Operating Instructions - RAMCRETE

Operating Instructionsfor machine operator and maintenance staff

always keep by the machine

Stationaryconcrete pump BSA 1407 D5

Machine no. 214490278

21−09−09

The paper on which this document is printed is 100% chlorine free E Putzmeister Concrete Pumps GmbH 1994

Translation of the original Operating Instructions

Putzmeister Worldwide

Deutsch�landPM

Putzmeister Concrete Pumps GmbHMax−Eyth−Straße 10D− 72631 Aichtal

+49−7127−599−0

+49−7127−599−520

[email protected]

www.putzmeister.de

EspañaPME

Putzmeister Ibérica S.A.Camino de Hormigueras 173Pol. Ind. VallecasE− 28031 Madrid

+34−91−428 81 00

+34−91−428 81 43

[email protected]

www.putzmeister.es

FrancePMF

Putzmeister France3, rue Paul Henri SpaakZAE Jean Monnet77240 Vert Saint Denis

+33−164 64 39 39

+33−164 64 39 29

[email protected]

www.putzmeister.fr

Great BritainPMUK

Putzmeister LimitedCarrwood RoadGB−ChesterfieldDerbyshire S41 9QB

+44−1246−2642 00

+44−1246−26 00 77

[email protected]

www.putzmeister.co.uk

TürkiyePTR

Putzmeister Makine Sanayi ve Tic. A.�G.O.Pa�a Mah.Nam�k Kemal Bulvar� No: 659500 Çerkezköy / TEK�RDA�

+90−282−735−1000

+90−282−738−1001

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www.putzmeister.com.tr

USAPMA

Putzmeister America1733 90th StreetSturtevant, WI 53177 USA

+1−262−886−3200

+1−262−886−3212

[email protected]

www.putzmeister.com

South AfricaPMSA

Putzmeister S.A. (Pty) Ltd.Cnr. Bramm & Citrus St. HoneydewP.O.Box 5146 ZA 2118 CrestaSouth Africa

+27−11−794−37 90

+27−11−794−41 19

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www.putzmeister.co.za

IndiaPCM

Putzmeister Concrete Machines Pvt LtdPlot No. N4, Phase IVVerna Industrial Estate, Verna SalceteGoa−403722

+91�832�6696000

+91�832−6696300

[email protected]

www.pmw.co.in

JapanPMJ

Putzmeister Japan Co. Ltd.

7−4 Misawa, Tomisato−shiChiba 286−0225, Japan

+81−476−36−8907

+81−476−36−8908

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www.putzmeister.jp

KoreaPMK

Putzmeister Korea Co. Ltd.59 Huimanggongwon−ro, Chungwang−DongShihwa Ind. complex 2 MA 707−1 HOShihung−city, Kyonggi−Do, Korea

+82−31−433−4541

+82−31−498−7230

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Russ�landPMR

OOO �Putzmeister−Rus�Urgumskaja Straße 4, Geb. 31129343 Moskau, Russia

+7−495−775−22−37

+7−495−775−22−34

[email protected]

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BP00_030_0911EN

de Übersetzung der Originalbetriebsanleitung

bg Ïðåâîä íà îðèãèíàëíî Ðúêîâîäñòâî çà ðàáîòà

cs P�eklad originálního návodu k obsluze

da Oversættelse af den originale driftsvejledning

el MetÜfrash tou prwtotýpou twn odhgiþn leitourgßaj

en Translation of the original Operating Instructions

es Traducción de las instrucciones de servicio originales

et Algupärase kasutusjuhendi tõlge

fi Alkuperäisen käyttöohjeen käännös

fr Traduction des instructions de service originales

hr Prijevod izvornika naputka za uporabu

hu Eredeti üzemeltetési útmutató fordítása

it Traduzione delle istruzioni d’uso originali

lt Eksploatavimo instrukcijos originalo vertimas

lv Lieto�anas pam�c�bas tulkojums no ori�in�lvalodas

nl Vertaling van de oorspronkelijke gebruiksaanwijzing

no Oversettelse av original brukerhåndbok

pl T�umaczenie oryginalnej instrukcji eksploatacji

pt Tradução das Instruções de funcionamento originais

ro Traducerea instruc�iunilor de func�ionare originale

ru Gthtdjl abhvtzzjuj herjdjlcndf gj ärcgkefnfwbb

sk Preklad originálneho návodu na obsluhu

sl Prevod izvirnih navodil za uporabo

sv Översättning av original instruktionsbok

tr Orijinal kullan�m k�lavuzunun tercümesi

BP00_030_0911EN

Table of contents

Table�of�contents

I214490278

1 Guide to the Operating Instructions 1.1 Foreword 1 — 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 Icons and symbols 1 — 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 Safety regulations 2.1 Definition of terms 2 — 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1.1 Machine 2 � 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1.2 Concrete pump 2 � 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1.3 Arm assembly 2 � 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1.4 Placing boom 2 � 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1.5 Base structure 2 � 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1.6 Truck mixer 2 � 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1.7 Delivery line systems 2 � 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1.8 End hose 2 � 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1.9 Manufacturer 2 � 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1.10 Operator 2 � 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1.11 Machine operator 2 � 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1.12 Hoseman 2 � 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1.13 Signaller and other auxiliary personnel 2 � 2 . . . . . . . . . . . . . . . . . . 2.1.14 Truck mixer driver 2 � 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1.15 Subject expert 2 � 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1.16 Qualified personnel 2 � 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1.17 After Sales Service personnel 2 � 3 . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1.18 Maintenance 2 � 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1.19 Place of work, working area, danger zone 2 � 4 . . . . . . . . . . . . . . .

2.2 Designated use 2 — 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.1 Retesting (safety inspection) 2 � 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.2 Inspection intervals for retesting 2 � 11 . . . . . . . . . . . . . . . . . . . . . . .

2.3 Improper use 2 — 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.1 Transporting goods 2 � 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.2 Lifting loads 2 � 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.3 Removing obstacles 2 � 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.4 Extending the reach 2 � 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.5 Extending the placing boom and end hose 2 � 13 . . . . . . . . . . . . . .


II 214490278

2.3.6 Impermissible end hose 2 � 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.7 Impermissible working area 2 � 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.8 Climbing the placing boom 2 � 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.9 High�pressure delivery 2 � 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.10 Accessories and attachments 2 � 15 . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.11 Changes to the machine 2 � 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4 Exclusion of liability 2 — 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5 Personnel 2 — 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.1 Requirements 2 � 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.2 Qualifications 2 � 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.3 Responsibility of the machine operator 2 � 16 . . . . . . . . . . . . . . . . . .

2.6 Operating Instructions, operating procedures and other regulations 2 — 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6.1 Operating Instructions 2 � 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6.2 Operating procedures 2 � 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6.3 Other regulations 2 � 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.7 Personal protective equipment 2 — 19 . . . . . . . . . . . . . . . . . . . . . . .

2.8 Before working with the machine 2 — 21 . . . . . . . . . . . . . . . . . . . . . 2.8.1 Checking that the machine is ready for operation 2 � 21 . . . . . . . . 2.8.2 Rendering the machine ready for operation 2 � 21 . . . . . . . . . . . . .

2.9 Danger due to high voltage 2 — 22 . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9.1 High−voltage lines 2 � 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9.2 Discharge voltage pattern 2 � 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9.3 Clearances 2 � 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9.4 High�voltage warning devices 2 � 24 . . . . . . . . . . . . . . . . . . . . . . . . . 2.9.5 Procedure in the event of a flash over 2 � 24 . . . . . . . . . . . . . . . . . . . 2.9.6 Earthing in the event of electrostatic charging 2 � 25 . . . . . . . . . . . 2.9.7 Earthing on construction sites with special equipment 2 � 25 . . . .

2.10 Stationary machines 2 — 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10.1 Set�up site 2 � 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10.2 Stationary placing booms 2 � 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10.3 Lifting machines and components 2 � 27 . . . . . . . . . . . . . . . . . . . . . . 2.10.4 Loading and transporting 2 � 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.11 Mobile machines 2 — 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11.1 Set�up site 2 � 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


III214490278

2.11.2 Supporting ground 2 � 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11.3 Corner bearing loads 2 � 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11.4 Supports 2 � 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11.5 Driving 2 � 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11.6 Towing 2 � 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11.7 Loading 2 � 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.12 Placing booms 2 — 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12.1 Unfolding the placing boom 2 � 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12.2 End hose 2 � 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12.3 Guiding the end hose ergonomically 2 � 39 . . . . . . . . . . . . . . . . . . . 2.12.4 Connecting drills 2 � 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12.5 Procedure in storms 2 � 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12.6 Concreting in cold weather 2 � 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.13 Delivery line systems 2 — 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13.1 Suitable delivery lines 2 � 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13.2 Securing delivery lines 2 � 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13.3 Leak tightness and blockages 2 � 42 . . . . . . . . . . . . . . . . . . . . . . . . . 2.13.4 Opening delivery lines 2 � 43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13.5 Clearance to delivery lines 2 � 43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13.6 Fastening delivery lines 2 � 43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13.7 Continuation delivery lines 2 � 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13.8 Devices for shutting off, diverting or cleaning delivery lines 2 � 44

2.14 Pumping operations 2 — 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14.1 Place of work 2 � 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14.2 Safety 2 � 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14.3 Remote control 2 � 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14.4 Moving machine components and hot surfaces 2 � 46 . . . . . . . . . . 2.14.5 Constant observation of the machine 2 � 47 . . . . . . . . . . . . . . . . . . . 2.14.6 Truck mixer 2 � 47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.15 Cleaning 2 — 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15.1 General 2 � 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15.2 Cleaning agents 2 � 49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15.3 Cleaning with compressed air 2 � 50 . . . . . . . . . . . . . . . . . . . . . . . . . 2.15.4 Protection against water 2 � 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15.5 Post−cleaning procedure 2 � 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


IV 214490278

3 General technical description 3.1 Overview 3 — 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 Safety equipment 3 — 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 Technical data 3 — 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3.1 Electromagnetic compatibility (EMC) 3 � 6 . . . . . . . . . . . . . . . . . . . 3.3.2 Machine rating plate 3 � 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3.3 Sound pressure level 3 � 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3.4 Sound power level 3 � 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4 Description of the functions 3 — 10 . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4.1 Chassis 3 � 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4.2 Static base structure 3 � 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4.3 Support legs 3 � 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4.4 Pump 3 � 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4.5 Agitator 3 � 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5 General conditions for using a concrete pump 3 — 15 . . . . . . . . 3.5.1 Service life 3 � 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5.2 Site of use 3 � 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5.3 Height of job 3 � 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5.4 Operating temperature 3 � 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5.5 Centralized lubrication system 3 � 18 . . . . . . . . . . . . . . . . . . . . . . . . .


V214490278

3.6 Electrical control devices 3 — 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6.1 Control cabinet with SPC display unit 3 � 21 . . . . . . . . . . . . . . . . . . . 3.6.2 SPC display unit 3 � 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6.3 Ergonic Output Control (EOC) 3 � 66 . . . . . . . . . . . . . . . . . . . . . . . . . 3.6.4 Fuse box 3 � 69 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6.5 Cable remote control 3 � 74 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6.6 EMERGENCY STOP button 3 � 76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6.7 Agitator safety cutout (RSA) 3 � 78 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6.8 Magnetic switches distributor casing 3 � 80 . . . . . . . . . . . . . . . . . . . 3.6.9 Magnetic switch connector 3 � 83 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.7 Hydraulic control devices 3 — 85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7.1 Output controller 3 � 86 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7.2 Water pump lever 3 � 87 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7.3 Pump control system 3 � 88 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7.4 Agitator emergency operation 3 � 89 . . . . . . . . . . . . . . . . . . . . . . . . . 3.7.5 Pressure gauge 3 � 90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7.6 Filter condition 3 � 90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.8 Other components 3 — 91 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8.1 Flushing water pump 3 � 92 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8.2 Vibrator 3 � 94 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8.3 Exhaust after treatment system 3 � 95 . . . . . . . . . . . . . . . . . . . . . . . .


VI 214490278

4 Starting up 4.1 Visual checks 4 — 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.1 Hydraulic system 4 � 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.2 Functional fluids 4 � 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.3 Condensate water 4 � 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.4 Lubrication points 4 � 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.5 Hydraulic fluid radiator 4 � 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.6 Water box 4 � 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.7 Parts in contact with�concrete 4 � 5 . . . . . . . . . . . . . . . . . . . . . . . . .

4.2 Test run 4 — 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.1 Switching on the�machine 4 � 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3 Function checks 4 — 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.1 Pump 4 � 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.2 EMERGENCY STOP buttons 4 � 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.3 Function check of the agitator safety cutout (RSA) 4 � 12 . . . . . . . 4.3.4 Acknowledging the agitator safety cutout 4 � 14 . . . . . . . . . . . . . . . 4.3.5 Filter condition 4 � 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.6 Agitator 4 � 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.7 Flushing water pump 4 � 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.8 Vibrator 4 � 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.9 Switching off the machine 4 � 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


VII214490278

5 Transport, setting up and connection 5.1 Transport 5 — 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.1 Loading 5 � 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.2 Lifting eyes 5 � 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.3 Chassis 5 � 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.4 F�8 chassis 5 � 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.5 F�25 chassis 5 � 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.6 F�80 chassis 5 � 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.7 Crawler track 5 � 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.8 Static base structure 5 � 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 Hand signals for driving 5 — 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3 Requirements for the set–up site 5 — 10 . . . . . . . . . . . . . . . . . . . . .

5.4 Setting up 5 — 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5 Stationary delivery line 5 — 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5.1 Danger zone 5 � 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5.2 Instructions for laying the line 5 � 20 . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5.3 Fastening 5 � 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5.4 SK delivery line system 5 � 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.6 Rod side – piston side feed 5 — 27 . . . . . . . . . . . . . . . . . . . . . . . . . .

5.7 Flushing water pump 5 — 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


VIII 214490278

6 Pumping operations 6.1 Preconditions 6 — 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1.1 Remote control 6 � 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2 Hand signals for pumping 6 — 3 . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3 Filling the machine with fuel 6 — 5 . . . . . . . . . . . . . . . . . . . . . . . . .

6.4 Filling the DEF container 6 — 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.5 Considering concrete properties 6 — 10 . . . . . . . . . . . . . . . . . . . . .

6.6 Filling the agitator hopper 6 — 11 . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.7 Starting pumping 6 — 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.8 Pumping 6 — 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8.1 Monitoring 6 � 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8.2 Blockages 6 � 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8.3 Breaks in pumping 6 � 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8.4 Engine 6 � 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8.5 Overheating 6 � 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8.6 Exhaust after treatment system 6 � 20 . . . . . . . . . . . . . . . . . . . . . . . . 6.8.7 Restarting 6 � 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.9 Cleaning 6 — 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9.1 Preparations for�cleaning 6 � 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9.2 Delivery line 6 � 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9.3 Hopper, delivery cylinder and S�transfer tube 6 � 41 . . . . . . . . . . . . 6.9.4 Post�cleaning procedure 6 � 47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.10 Measures for preserving the value of stationary concrete pumps placed in storage 6 — 49 . . . . . . . . . . . . . . . . . . . .


IX214490278

Glossary G–1 Symbols for concrete pumps in accordance with

German Mechanical Engineering Association Standard (VDMA 24119) G — 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

G–2 Key to the symbols for concrete pumps G — 7 . . . . . . . . . . . . . .

G–3 Abbreviations and technical terms G — 15 . . . . . . . . . . . . . . . . . . .

Index of key words

Guide�to�the�Operating�Instructions

1��IBP01_001_0802EN

1 Guide to the Operating Instructions

In this chapter you will find notes and information that will help youuse these Operating Instructions. Do not hesitate to contact us if youhave any queries:

Putzmeister Concrete Pumps GmbHAfter Sales DepartmentMax−Eyth−Straße 10D−72631 AichtalGermanyTelephone +49 7127 599−0Telefax +49 7127 599−520e−mail: [email protected]

or the Branch or Works Agency that looks after you.

Address:

Telephone:

Telefax:

e−mail:


1��II BP01_001_0802EN


1��1AP01_002_0802EN

The aim of these Operating Instructions is to familiarize the user withthe machine and to assist him in using the machine properly in vari�ous operations.

The Operating Instructions contain important information on how tooperate the machine safely, properly and economically. Observingthese instructions helps to avoid danger, to reduce repair costs anddowntimes, and to increase the reliability and service life of themachine.

The Operating Instructions must be supplemented by the relevantnational rules and regulations for accident prevention and environ�mental protection.

The Operating Instructions must always be available wherever themachine is in use.

These Operating Instructions must be read and applied by anyperson charged with carrying out work with and on the machine eg− in operation, including setting up, fault rectification in the course of

work, removal of production waste, maintenance and disposal offuels and consumables;

− in service (maintenance, inspection, repair); and/or− transport.

The generally−recognized rules of technology for safe and properworking must be observed in addition to the Operating Instructionsand mandatory rules and regulations for accident prevention andenvironmental protection in the country and place of use of themachine.

1.1 Foreword


1��2 AP01_002_0802EN

The Branch or Agent serving you, or the Aichtal Works, will be happyto give you more information should you have any questions follow�ing your study of the Operating Instructions.

You will make it much easier for us to answer any questions if youcan give us the details of the machine model and the machinenumber.

These Operating Instructions do not describe the engine; the en�closed operating instructions issued by the engine manufacturerapply for this.

Modifications are made from time to time in the interests of constantimprovement and it could be possible that we were unable to takethese into consideration when these Operating Instructions wereprinted.

The copy of the Operating Instructions intended for the machine willbe replaced in full in the event of any amendment.

The reproduction, distribution and utilization of this document as wellas the communication of its contents to others without explicit author�ization is prohibited. Offenders will be held liable for the payment ofdamages. All rights reserved in the event of the grant of a patent,utility model or design.

© Putzmeister Concrete Pumps GmbH 1994


1��3BP01_003_0601EN

The following icons and symbols are used in the OperatingInstructions:

" Task symbolText following this symbol describes tasks which you are required towork through from top to bottom in the sequence shown.

� Text following this symbol describes the result or effect of an action.

See also the maintenance cards:This icon is used to refer to the maintenance cards required,possibly as a supplement to the maintenance card you are currentlyreading.

The following special tools are required:This icon identifies the special tools necessary to carry out the work.Normal tools, i.e. commercially−available tools or tools carried in thetruck, are not specially listed.

Environmental protectionParticular specifications regarding environmental protection areintroduced by the icon shown, the words �Environmental protection"printed in bold, and a line. The associated text is printed in italicsand ends with another line.

NoteParticular information regarding the economic use of the machine isintroduced by the icon shown, the word �Note" printed in bold, anda�line. The associated text is printed in italics and ends with anotherline.

CautionParticular information or rules or prohibitions intended to preventdamage are introduced by the icon shown, the word �Caution"printed in bold, and a line. The associated text is printed in italicsand ends with another line.

1.2 Icons and symbols


1��4 BP01_003_0601EN

DangerParticular information or rules or prohibitions intended to preventpersonal injury or significant damage are introduced by the iconshown, the word �Danger" printed in bold, and a line. The associatedtext is printed in italics and ends with another line.

The appropriate icon will be used if it is possible to identify the sourceof the danger precisely.

Danger of fireThis icon is used to identify actions for which there is a particulardanger of fire.

Danger of explosionThis icon is used to identify actions during which there is the dangerof an explosion. The explosion may also be caused by pressurebeing released suddenly.

Falling items�This icon is used to identify actions in which there is a risk of injurycaused by parts falling down.

Danger of crushingThis icon is used to identify actions during which there is the dangerof being crushed.


1��5BP01_003_0601EN

Suspended loadThis icon is used to identify actions in which suspended loads mayfall down.

High voltageThis icon is used to identify actions in which there is the danger ofelectrocution, possibly with lethal consequences.

Danger of burningThis icon is used to identify actions in which there is a danger ofburning from chemical substances which are not specificallydescribed.

Danger of burningThis icon is used to identify actions in which there is a danger ofburning from battery acid.

Danger of poisoningThis icon is used to identify actions in which there is a danger ofpoisoning by inhalation of gases, ingestion of or contact withsubstances.


1��6 AusgleichsseiteEN

Safety�regulations

2��IBP03_081_1701EN

2 Safety regulations

These safety regulations conform to the chapters �Terms, definitions,requirements" and �Starting up and working with the machine" in theGerman Engineering Federation (VDMA) brochure

�Safety manual Concrete delivery and placing machines".

Here you will find a summary of the most important safety regula�tions. This chapter is particularly suitable as an initial basic instruc�tion for new employees.

NoteSpecial safety regulations may be necessary for some tasks. Thesespecial safety regulations will only be found in the description of theparticular task.

We include here a listing of regulations and safety standards for yourinformation:� EN 12001, Conveying, spraying and placing machines for con�

crete and mortar� EN 12100, Safety of machinery,� EN 60204−1, Electrical equipment of machines.� In the Federal Republic of Germany: DGUV�Regulation�101−012,

Concrete pumps and placing booms.


2��II BP03_081_1701EN


2��1BP03_082_2101EN

The terms used in this Safety Manual are explained below, alongwith descriptions of the requirements placed on specific groups ofpeople.

For the purposes of this Safety Manual, concrete delivery and plac�ing machines are defined as:− Truck−mounted concrete pumps (an ensemble of truck and con�

crete pump with and without placing boom). The safety regula�tions issued by the truck manufacturer also apply to the truck.

− Truck mixer concrete pump (an ensemble of truck mixer, con�crete pump and placing boom). The safety regulations issued bythe truck mixer manufacturer and by the truck manufacturer alsoapply to truck mixer concrete pumps.

− Stationary concrete pumps− Stationary placing systems (an ensemble of placing boom and

base structure)

For the purposes of this Safety Manual, concrete pumps are de�fined as devices which are designed to deliver concrete to place�ment sites via pipes or hoses.

Arm assembly is a synonym for placing boom and can be used in�terchangeably.

For the purposes of this Safety Manual, placing booms are definedas powered, slewable devices consisting of one or more swingingor folding sections for guiding the delivery line.

For the purposes of this Safety Manual, base structures are definedas equipment which is designed to hold a stationary placing boomto give the latter the required stability.

2.1 Definition of terms

2.1.1 Machine

2.1.2 Concrete pump

2.1.3 Arm assembly

2.1.4 Placing boom

2.1.5 Base structure


2��2 BP03_082_2101EN

For the purposes of this Safety Manual, truck mixers are defined asvehicles with mixing equipment for transporting concrete.

For the purposes of this Safety Manual, delivery line systems aredefined as self−contained pipes or hoses in which concrete ispumped from the concrete pump to the placement site. Devices forshutting off, diverting or cleaning delivery lines can be integratedinto delivery line systems.

For the purposes of this Safety Manual, end hose is defined as thehose that is fitted on the placing boom at the end of the delivery linefor distributing the concrete. There must be no couplings, spouts,discharge stops or other items fixed to the outlet end of the endhose unless they are approved by the manufacturer.

Any natural or legal person that markets a machine or incompletemachine that is dealt with in this Safety Manual.

Authorized representative of the owner of the concrete pumpsand/or placing booms. The operator is responsible for the use ofthese machines.

Persons trained in and charged with the operation of concretepumps and placing booms.

Persons instructed by the site management in how an end hose isguided. Hosemen must be able to independently evaluate all dan�gerous situations which may occur in the area of the end hose andreact according to the situation.

Persons instructed by the site management to help the machine op�erator in his work if the latter is unable to observe all areas of oper�ation and danger zones. Signallers must be able to independentlyevaluate all dangerous situations which may occur when workingwith a concrete pump and/or placing boom and react according tothe situation. The signaller must have a suitable means of communi�cation with the machine operator.

2.1.6 Truck mixer

2.1.7 Delivery line systems

2.1.8 End hose

2.1.9 Manufacturer

2.1.10 Operator

2.1.11 Machine operator

2.1.12 Hoseman

2.1.13 Signaller and otherauxiliary personnel


2��3BP03_082_2101EN

Persons who supply the concrete pump with concrete from a truckmixer. Truck mixer drivers must be instructed by the machine oper�ator to operate the operating elements on the concrete pump pro�vided for their use. Truck mixer drivers must be able to indepen�dently evaluate all dangerous situations which may occur whenworking in the area of the hopper of a concrete pump and react ac�cording to the situation.

For the purposes of this Safety Manual, a subject expert is definedas a person who, through their professional training, their pro�fessional experience and their recent professional activity, has therequired specialist knowledge to inspect the tools.

Persons who have completed specialist training for a particular ac�tivity which qualifies them to carry out their roles.

Qualified personnel employed by the manufacturer who are respon�sible in particular for maintenance of the machine.

Maintenance includes all measures required to inspect, maintainand repair a machine.

2.1.14 Truck mixer driver

2.1.15 Subject expert

2.1.16 Qualified personnel

2.1.17 After Sales Servicepersonnel

2.1.18 Maintenance


2��4 BP03_082_2101EN

2.1.19 Place of work, working area, danger zone

ab0005

14 6 7

1

2

3

5

6

8

9

10

11

12

Example

ab0010

14

1

1

2

3

3

4

4

5

66

8

9

11

11 12

13

13

10

13

Example

Mobile machines

Stationary machines


2��5BP03_082_2101EN

Pos. 0 Designation Explanation

1Pl f k

Machine operator In normal operation, with the remote control2 Place of work

(during pumpHoseman At the end hose in the danger zone

3 (during pump�ing oper

Signaller In the machine operator’s range of vision4

ing oper�ations)

Auxiliary personnel As machine operators of the manual placing system5

ations)Truck mixer driver At the hopper in the danger zone

6Working area

PermittedArea with a radius of the reach of the placing boom+ end hose length

7Working area

ImpermissibleThe end hose must not be moved backwards be�yond the vertical of the placing boom

8 At the end hose

Risk of injury when pumping is started, duringpumping operations, when removing a blockageand during cleaning procedures. The diameter ofthe danger zone is twice the end hose length.

9Beneath the placingboom

Risk of injury from falling items

10 Danger zone

Area of the supportlegs and feetor area of the basestructure

Risk of crushing when setting up or dismantling themachine

11 On the machineAny presence on or below the machine when thepump is in operation is prohibited

12 At the hopperRisk of injury during cleaning procedures and whenthe hopper is being filled using a truck mixer

13Area of the deliveryline systems

Hazard posed if lines burst, risk of injury from crush�ing or shearing, particularly with gate valves

14 Structure or area being concreted Example


2��6 BP03_082_2101EN

The place of work is the area in which people must remain in orderto carry out the work.

The machine operator’s place of work is with the remote controlwhen the pump is in operation. The place of work must be selectedso as to allow visual contact with the placement site and the truckmixer driver, and so that the working area can be observed at thesame time. A signaller must otherwise be used.

The machine operator’s place of work is with the machine when thisis being set up or prepared for driving.

The hoseman’s place of work is within the danger zone of the endhose, but not beneath the placing boom. This requires a greaterlevel of caution. The hoseman and machine operator must have vis�ual contact.

The truck mixer driver’s place of work is in the danger zone of thehopper and at operating elements for the agitator and truck mixer.This requires a greater level of caution. The truck mixer driver andmachine operator must have visual contact.

The working area is the area in which work is carried out with or onthe machine. Parts of the working area can become danger zonesdepending on the operation being carried out and the position ofthe placing boom.

The working area must be secured and clearly identified. Suitablepersonal protective equipment is required in the working area. Themachine operator is responsible for safety in the working area of themachine whilst the machine is in use.

Because of their high manoeuvrability, some placing booms canalso be shifted into positions for which they are not designed. Thismay overload or damage the placing boom. Placing booms musttherefore only be moved within the permitted working area (see alsopage�2��14).

Place of work

Place of work � ma�chine operator

Place of work � hose�man

Place of work � truckmixer driver

Working area

Impermissible workingarea


2��7BP03_082_2101EN

The danger zone is the area surrounding the machine, in whichpeople may be at risk of injury from movements required by thework.

The danger zone varies within the working area and depends onthe activity being carried out and the position of the placing boom,if one is present. Danger zones must be secured and clearly identi�fied. The machine operator must be capable of seeing the dangerzone at all times and under all circumstances. If necessary, he mustappoint a signaller to supervise the danger zone.

Depending on the working situation, places of work may oc�casionally fall within the danger zone, especially the place of workof the hoseman and the truck mixer driver. If a place of work fallswithin the danger zone, increased caution is required and suitablepersonal protective equipment is prescribed. Persons who are auth�orized to be present in such a place of work must use their owndiscretion to assess dangerous situations and be able to react ac�cording to the situation.

The machine operator is responsible for safety in the danger zoneof the machine whilst the machine is in use.

The machine operator must stop work immediately and press theEMERGENCY STOP button if an unauthorized person enters thedanger zone.

There is a risk of crushing in the swing�out and extension zone forthe supports.

The danger zone when working with the placing boom is the zoneover which the placing boom is slewed. In this area there is a risk ofinjury from falling concrete and delivery line components.

Danger zone

Support legs and sup�port feet

Placing boom


2��8 BP03_082_2101EN

All the time the vehicle is in operation, there is a risk of injury on andbelow the machine from moving parts and bursting delivery lines orhydraulic hoses, as well as a risk of falling on slippery surfaces orsteps.

The danger zone when pumping is started, during pumping oper�ations, when removing a blockage and during cleaning proceduresis the area around the end hose in which the end hose may swingout. The diameter of the danger zone is twice the end hose length.

In the area of the hopper, there is a risk of becoming trapped be�tween the truck mixer and the hopper and of being sprayed withconcrete. There is a risk of being crushed and of injury by shearingfrom the transfer tube. There is a risk of becoming caught in the ro�tating agitator.

In the area around the delivery line systems there is a risk of injuryfrom the delivery line bursting if there is an abrupt rise in pressure.There is a risk of crushing and injury by shearing with devices inte�grated in delivery line systems.

Machine

End hose

Hopper

Delivery line systems


2��9BP03_082_2101EN

The machine must only be operated as intended and in technicallyperfect condition. All protective and safety�oriented devices, par�ticularly removable protective devices and EMERGENCY STOP de�vices, must be available and fully functional.

The machine is designed exclusively for the delivery and placing ofconcrete up to a bulk density of 2400 kg/m3. It must only be usedfor pumping operations on construction sites. The maximum con�crete pressure must not exceed that specified on the rating plate orin the check book.

You must also observe the Operating Instructions and comply withthe intervals and conditions for inspections (particularly retesting)and maintenance work in order to operate the machine within thelimits of its proper use.

2.2 Designated use


2��10 BP03_082_2101EN

After initial commissioning of the machine, the operational safety ofthe machine must be checked regularly by a subject expert. Theinspection intervals depend on the age of the machine. The olderthe machine, the greater the probability of damage. For this reason,regular retesting of the machine, appropriate to its age, must becarried out in order to detect damage in good time. Retestingshould be carried out in accordance with the inspection intervalslisted below.

Retesting must consist of the following:− Retesting of the condition of the components and equipment with

regard to the formation of cracks, damage, wear, corrosion andother changes;

− Retesting of the completeness and effectiveness of the safetyequipment;

− Retesting to find out whether any defects which are found duringthe tests mentioned above and which could affect safety havebeen adequately rectified.

Retesting must include components which are used in conjunctionwith the machine (in particular, delivery line components and acces�sories).

Furthermore, information provided by the manufacturer to the oper�ator with reference to special instructions for maintenance and in�spection must be observed.

2.2.1 Retesting (safety in-spection)


2��11BP03_082_2101EN

The inspection intervals are fixed as follows:

Machines up to and including 5�years old:Inspect after every 1000�operating hours or 1�year, whichever issoonest. The interval is repeated after every retest.

Machines more than 5�years old:Inspect after every 500�operating hours or 1�year, whichever issoonest. The interval is repeated after every retest.

Machines more than 10�years old:Inspect after every 250�operating hours or 1�year, whichever issoonest. The interval is repeated after every retest.

The day of initial commissioning in accordance with the handoverreport and the machine’s operating hours meter are definitive forthe intervals. This operating hours meter records the hours ofpumping operations. The operating hours meter must always bekept in good working order. It must not be tampered with. For ma�chines without an operating hours meter, the operating hours mustbe recorded in a traceable form in writing.

Retesting must be arranged by the operator. The results of retestingmust be entered in the check book and signed. The check bookmust always be kept with the machine and must be produced uponthe request of the national supervisory bodies.

Notwithstanding national legislation, the operator can be liable inthe event of damage, if it is proved that the damage has arisen as aconsequence of regular retesting not being properly carried out.

If retesting is not carried out, the manufacturer will assume that themachine has been shut down. When the machine is restarted,retesting must be carried out.

2.2.2 Inspection intervalsfor retesting


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Any use of the machine which is not described in section�2.2,�en�titled �Designated�use", or which extends beyond the uses de�scribed in this section is deemed to be contrary to designated use.The manufacturer accepts no liability for damage resulting fromsuch use. Some examples of conceivable improper uses are givenbelow.

The machine must not be used for the transport of goods, exceptfor carrying the accessories used for the machine, such as pipes,hoses, etc. The maximum permissible gross weight may not be ex�ceeded.

The placing boom must never be used for lifting loads.

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The placing boom must not be used under any circumstances toremove obstacles. This would overload the placing boom, causingdamage and endangering people.

It is prohibited to attach an extension (e.g. freely suspended cross�beam) to the end hose or placing boom tip in order to extend thereach or to pump at an angle. Since the placing boom and the lift�ing equipment for the extension have differing pivot points andmodes of control, it is not possible to co−ordinate their movements.

2.3 Improper use

2.3.1 Transporting goods

2.3.2 Lifting loads

2.3.3 Removing obstacles

2.3.4 Extending the reach


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Extension of the placing boom and end hose beyond the lengthspecified on the rating plate is forbidden.

If the manufacturer defines the weight rather than the length of theend hose, you can use a reducer pipe with a longer end hose, forexample. The quoted gross weight must not be exceeded.

If a longer end hose is used, the diameter of the danger zone isalso increased (see also page�2��38).

End hoses with a length of more than 4�m must not be guided byhand.

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There must be no couplings, spouts, discharge stops or other itemsfixed to the outlet end of the end hose unless they are approved bythe manufacturer.

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2.3.5 Extending the placingboom and end hose

2.3.6 Impermissible endhose


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During pumping operations, the end hose must not be movedbackwards beyond the vertical axis of rotation of the placing boom.

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In addition to this, additional impermissible working areas exist, de�pending on the machine model and manufacturer, which are de�scribed in the Operating Instructions.

It is prohibited to climb the placing boom, to stand on top of it or tomisuse it as a working platform or climbing aid.

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2.3.7 Impermissible work-ing area

2.3.8 Climbing the placingboom


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It is prohibited to deliver concrete at high pressure (delivery pres�sure greater than 85bar) through the delivery line of the placingboom. Delivery line elements are marked with the maximum per�missible delivery pressure. The delivery line and end hose are onlysuitable for delivery pressures of up to 85bar until the wear thresh�old is reached. For the wear threshold, refer to the Operating In�structions for the machine.

It is prohibited to fit accessories and attachments to the machine ifthey have not been expressly approved for use on this machine bythe manufacturer.

You are not allowed to carry out your own changes to the machine.Changes must always be approved by the manufacturer.

Where the manufacturer’s delivery conditions are agreed, liabilitywill be as described in the provisions there. The manufacturer is notliable for damage in cases specified there.

Unless the responsibility of the manufacturer, the warranty will beinvalidated in the following situations in particular:− use contrary to designated use− incorrect operation, maintenance and repair− use of spare parts or accessories other than original manufac�

turer’s spare parts and accessories or their equivalents− conversions, alterations or modifications to the machine− fitting of accessories and attachments not approved by the

manufacturer− adjustment of safety pressures, speeds of movement, power out�

puts, speeds of rotation and other settings to values other thanthose set in the works

The operator must ensure that only persons who are qualified orhave received the necessary instruction work on or with the ma�chine. It is the responsibility of the operator to carry out regular (e.g.annual) safety briefings for their employees. Suitable training canbe requested from the machine manufacturer. The operator mustclearly define who is responsible for operation and maintenance ofthe machine. The operating company must also ensure that onlypersons commissioned to work on the machine do so. In addition,the operator should provide the necessary personal protectiveequipment.

2.3.9 High-pressure deliv-ery

2.3.10 Accessories and at-tachments

2.3.11 Changes to the ma-chine

2.4 Exclusion of liability

2.5 Personnel


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Persons operating or carrying out maintenance work on the ma�chine must meet the following requirements:− They must be aged 18 years or over.− They must be physically and mentally capable.− They must be physiologically capable (rested and not under the

influence of alcohol, drugs or medication).− They must have been instructed in the operation and mainten�

ance of the machine.− They must have demonstrated their competence to the operator.− They can be expected to reliably execute the tasks with which

they are charged.

The operating personnel must not wear loose garments or jewellery,including rings. Long hair which is not tied back must be coveredby a hair net. There is a risk of injury, in particular from being caughtor trapped by moving parts.

All persons working on or with the machine must concentrate on thetask at hand and not be distracted, particularly by smartphonesand music played through headphones.

Persons who are being trained, introduced and instructed in theuse of the machine are only permitted to operate the machineunder the constant supervision of experienced personnel.

If you do not have qualified personnel, suitable workshop equip�ment, etc. available, you should commission the manufacturer’sAfter Sales Department with the maintenance of your machine.

The operator must define the responsibility of the machine operator(including in respect to national road traffic regulations) and em�power the machine operator to reject instructions from third partiesprejudicial to safety. The machine operator must be able to rejectthe site of operations in the event of doubts regarding technicalsafety.

2.5.1 Requirements

2.5.2 Qualifications

2.5.3 Responsibility of themachine operator


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2.6 Operating Instructions, operating procedures and other regulations

Personnel that are authorised to work on the machine must haveread the Operating Instructions, particularly the "Safety Regula�tions" section, and the Safety Manual before working with the ma�chine. Reading the instructions after work has begun is too late.This applies especially to persons working only occasionally on themachine, e.�g. during setting up or maintenance.

As the operator, you must always make sure that the Operating In�structions are available. The Operating Instructions and check bookmust always be kept to hand at the site of use of the machine (inthe tool compartment or container provided for this purpose).

As the operator, you must have personnel working on the machineconfirm in writing their knowledge, understanding and applicationof the Operating Instructions and Safety Regulations and SafetyManual. At regular intervals of at least once a year, check that per�sonnel are conscious of safety and the hazards involved in theirwork and are taking account of the Operating Instructions.

Personnel entrusted with work on the machine must observe allsafety instructions and hazard warnings, and must be familiar withthe machine itself. You must practice all the operating proceduresdescribed in the Operating Instructions (extending the supports,operating the placing boom, shifting the placing boom into the driv�ing position, preparing the vehicle for moving, etc.) under thesupervision of a subject expert until you are certain you can ex�ecute them safely. Ask questions if there is something you have notunderstood. Begin operating the machine only once you are fullyand explicitly familiar with the layout and significance of all the con�trol and monitoring devices and the method of operation of the ma�chine.

2.6.1 Operating Instruc-tions


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The operator must produce operating procedures for their person�nel in accordance with national regulations. These operating pro�cedures must include instructions covering the duties involved insupervising and notifying special organisational features, e.g. or�ganization of work, working procedures or the personnel entrustedwith the work. Furthermore, reference must be made to other gen�erally valid legal and otherwise mandatory regulations relating toaccident prevention and environmental protection. Such regulationsmay also deal with handling hazardous substances, the issuing andwearing of personal protective equipment or with national roadtraffic regulations. You should familiarize yourself with the site ofoperations and with how to use fire extinguishers. Observe the fire�alarm and fire−fighting procedures.

The current regulations for concrete delivery and placing machinesas issued by:− The legal authorities in your country− national supervisory bodies− The responsible commercial liability insurance company.

2.6.2 Operating procedures

2.6.3 Other regulations


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In order to reduce risks to personnel, personal protective equip�ment must be used in so far as this is necessary or deemed to beso by regulations. All personnel working on or with the machinemust wear safety helmets, protective gloves and safety footwear.

Personal protective equipment must, as a minimum, comply withthe requirements of the specified standards.

Safety helmetA safety helmet protects your head against, for instance, falling con-crete or parts of the delivery line in the event of a hose bursting.(DIN EN 397; Industrial safety helmets)

Safety footwearSafety footwear protects your feet against falling objects and againstpenetration by projecting nails.(EN ISO 20345; Safety footwear for professional use; category S3)

Hearing protectorsHearing protectors protect you against the noise generated by themachine when you are standing close to it.(DIN EN 352-1; Hearing protectors – General requirements – Part 1:EarmuffsorDIN EN 352-3; Hearing protectors – General requirements – Part 3:Earmuffs on safety helmet)

2.7 Personal protectiveequipment


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Protective glovesProtective gloves protect your hands against aggressive or chemicalsubstances, as well as against mechanical effects (e.g. impact) andcutting injuries.(DIN EN 388; Protective gloves against mechanical risks;Class 1111)

Protective gogglesProtective goggles protect your eyes against injuries from concretespatters or other particles.(DIN EN 166; Personal eye-protection – Specifications)

Safety harnessWhen working at height, use the climbing aids and working plat-forms provided for reasons of safety or wear a safety harness. Therelevant national regulations must be complied with.(DIN EN 361; Personal Protective Equipment Against Falls from aHeight – Full Body Harnesses; Category III)

Face mask and respiratory protectionA face mask and respiratory protection protect you against particlesof building materials which could enter your body through your respi-ratory passages (e.g. concrete admixtures).(DIN EN 149; Respiratory protective devices – Filtering half masksto protect against particles – Requirements, testing, marking;Class FFP1)


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2.8 Before working with the machine

As machine operator, it is your responsibility to check the machinefor external damage and defects before any use of the machine.You must immediately report any changes (including changes in theworking characteristics) to the organization or person responsible.If necessary, shut the machine down immediately and secure it.

As machine operator, you are responsible for rendering the ma�chine ready for operation. This also includes topping up the func�tional fluids. Do not fill with fuel in enclosed spaces. Switch off theengine and the heating. Wipe up spilt fuel immediately. Do notsmoke or use a naked flame when handling fuel.

Set all the control and monitoring devices to the zero position be�fore you change the mode of control (control block, control consoleor remote control).

Never put the remote control down when the machine is ready foroperation. If this is unavoidable in exceptional cases, you mustswitch off the remote control, disconnect it and lock it away.

Never leave the machine when the engine is running or when theengine could be started by an unauthorized person. If you need toleave the machine, proceed as follows:− Switch off the remote control.− Disconnect the remote control and lock it away.− Switch off the ignition or the main switch.− Lock the control cabinet.

2.8.1 Checking that the ma-chine is ready foroperation

2.8.2 Rendering the ma-chine ready for oper-ation


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2.9 Danger due to high voltage

Whenever you touch a high−voltage line, there is a risk of death forall persons either on the machine or in its vicinity or who are con�nected to it (via the remote control, end hose, etc.). A spark canjump across from a high�voltage line even if you just approach itand this will energize the machine and the surrounding area.

In the event of a flash over, what is known as a �discharge voltagepattern" is formed in the vicinity of the machine. The voltage de�creases from the inside to the outside in this discharge voltage pat�tern. If you step inside this discharge voltage pattern, you willbridge different potentials. This will cause a voltage correspondingto the potential difference to flow through your body.

Maintain a minimum clearance from high�voltage lines in accord�ance with the following table. The minimum clearance is measuredin the horizontal when the placing boom is fully extended.

Rated voltage [V] Minimum clearance [m]

up to 1�kV 1.0

1�kV to 110�kV 3.0

110�kV to 220�kV 4.0

220�kV to 380�kV 5.0

unknown rated voltage 5.0

The specified clearances are minimum requirements. You must ob�serve any greater clearances that may be specified in the countryof use.

2.9.1 High–voltage lines

2.9.2 Discharge voltagepattern

2.9.3 Clearances


2��23BP03_082_2101EN

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When you set a minimum clearance, the possibility of the high−volt�age lines and the placing boom swaying in the wind must also betaken into consideration. You should further note that where air hu�midity is high, clearances greater than the minimum clearancesshown above are always necessary.

You must stand as close as possible to the unfolded placing boomif you wish to correctly estimate the movements of the boom and,above all, the clearance between the placing boom and obstaclesor high−voltage lines.

The same minimum clearances are necessary when driving underoverhead cables.

In the event that this minimum clearance cannot be maintainedunder all possible working positions, the power station responsiblemust be contacted and you must have the high�voltage lineswitched off.

Should you have any doubts, it is better to forgo the use of the plac�ing boom and to lay a separate delivery line, for instance.


2��24 BP03_082_2101EN

According to the current rules of engineering, high�voltage warningdevices do not meet a safety standard which enables minimumclearances to high�voltage lines that are smaller than the requiredminimum clearances to be used. Previous experience has shownthat high�voltage warning devices cannot make all situations inworking procedures safe. Flash overs and fatal accidents canoccur despite the use of a high�voltage warning device. You musttherefore always maintain the minimum clearances mentionedabove.

If, despite all precautions, a flash over occurs, stay calm and do notmove (potential differential) or touch anything.

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If your machine comes into contact with high−voltage lines:− Warn people standing outside the area not to approach or touch

the machine.− Have the power switched off.− Only leave the machine once you are sure that the line you have

touched or damaged has been de�energized.

2.9.4 High-voltage warningdevices

2.9.5 Procedure in theevent of a flash over


2��25BP03_082_2101EN

Electricity generator works are always equipped with automaticstart�up systems. If a circuit breaker trips, the short−circuited linewill be switched back on again after a brief interval. Brief intervalswhere the voltage is absent create a false sense of safety.

You must not move or rescue injured persons until a representativeof the power station has notified you that the line has been switchedoff.

A radio remote control system only protects the machine operator ifhe is standing outside the discharge voltage pattern.

Working in the vicinity of transmitters (radio transmitter, etc.) canresult in faults in the radio remote control system and dangerouselectrical charges in the machine. Persons who bridge the chargedparts to the earth are heavily charged on contact.

Machines in use in the vicinity of transmitters must be earthed. Thisearthing may be carried out by trained personnel.

Even when the machine is earthed, the safe clearances to high−voltage lines (see also page�2��22) must be maintained and theinstructions regarding storms and bad weather (see alsopage�2��40) must be observed.

If you have any further questions about earthing the machine,please contact site management or the operator of the machine.

When carrying out work in the area of special installations (particu�larly overhead lines for railways or substations), it may be the casethat the machine needs to be earthed upon request and in con�sultation with the operator of the special installation. This earthingmust only be carried out by qualified personnel.

Even when the machine is earthed, the safe clearances to high−voltage lines (see also page�2��22) must be maintained and theinstructions regarding storms and bad weather (see alsopage�2��40) must be observed.

2.9.6 Earthing in the eventof electrostatic charg-ing

2.9.7 Earthing on construc-tion sites with specialequipment


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2.10 Stationary machines

Stationary machines are generally used on a construction site for alengthy period. For this reason, site management should preparethe set�up site carefully. Site management must deliver the necess�ary documents in good time in order to be able to prepare thefoundations, base plates or similar on time.

When selecting the set�up site, remember that the machine must bedismantled and transported away again at the end of its use on site.The ambient conditions may change as construction work prog�resses.

Please also observe section�2.11.1, Mobile machines, Set−up site.

Stationary booms can be erected on tubular columns, lattice boomsor other base structures. The base/structural elements to which thebase structure is fixed must be able to withstand the forces andmoments transferred via the base structure, as specified in themanufacturer’s information. The base frame of the base structuremust be fastened in place so that it is level on the base/structuralelements in every direction. Check the documentation provided bythe manufacturer in this regard and the corresponding notes in theoperating instructions.

2.10.1 Set-up site

2.10.2 Stationary placingbooms


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Machines which are transported to the set�up site in individual partsor not under their own power must only be lifted with suitable liftingequipment in accordance with the specifications in the OperatingInstructions. The lifting gear on the machine must be capable of ac�cepting the lifting gear and lifting the load. No�one should standunder suspended loads. Before work is started, a subject expertmust check that the assembled machine is working properly.

Only use suitable means to load and transport stationary machines.Ensure that no�one can be injured by the machine tipping over orslipping.

If there are transport fixtures provided for the machine or its individ�ual components, only these should be used. The machine/compo�nents must be properly secured during transport. The transport ve�hicle and machine must be marked to conform with the road trafficregulations in the country concerned if they are to use the publichighway.

Please also observe section�2.11.5, Mobile machines, Driving.

2.10.3 Lifting machines andcomponents

2.10.4 Loading and trans-porting


2��28 BP03_082_2101EN

2.11 Mobile machines

Site management must prepare and assign the set−up site. It is themachine operator who takes responsibility for setting up the ma�chine safely. The machine operator must inspect the set�up site pro�posed by site management and must refuse to set the machine upat the site of operations if there are any doubts regarding safety.

As machine operator, you must familiarise yourself with the workingarea and surroundings before work is begun. The working area andsurroundings include, in particular, obstacles in the work and travel�ling areas, the load−bearing capacity of the supporting ground andany barriers separating the construction site from public roads.

The set�up site must have sufficient lighting to ensure safe oper�ation of the machine. Ensure that the set�up site is adequately lit.

Do not set up the machine in areas where equipment may fall down.

Incidents of overlapping with the working areas of other machines(particularly cranes, other placing booms, etc.) should be avoidedas far as possible. If this is not possible, special care and attentionis required when setting up and operating machinery. If necessary,you must use a signaller.

You must also check the approach route to the site where the ma�chine will be set up. If you are unsure whether the approach route issuitable, prepare the route before work is started. It is especiallynecessary to walk the approach route once in darkness and at duskor dawn. You should repeat this exercise again before leaving theconstruction site.

Always ask for a signaller if you need to reverse. If necessary, havethe approach route closed off or secured by signallers. Have anymaterials or equipment that hinder your approach removed.

2.11.1 Set-up site


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Find out the load−bearing capacity of the supporting ground. Thesite management will be able to state the permitted ground pres�sure. If the load−bearing capacity is unknown, assume the thatworst case scenario applies.

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The supporting ground must be level and even. If necessary, set upa level surface on top of the uneven ground. There must be novoids or other ground irregularities under the support feet. Asphalt,concrete slabs, etc. may have been washed out underneath. Neverset the machine up on backfilled ground, obvious or known voids oruneven ground.

The support area must be enlarged as required. Support blocksand timber blocks may be used to increase the support area. Thesupport timbers must be undamaged and free from ice, oil, grease,etc. The support blocks and timber blocks must be laid under thesupport plates such that the load is distributed uniformly and thesupport leg cannot slip off the side of the support.

Check the stability of the machine regularly during operation. Inter�rupt the pumping operation if the machine becomes unstable. Fac�tors which reduce stability include, for instance:− Modifications to the ground conditions, particularly caused by

rain water or the thawing of frozen ground− the support sinking on one side− fluid losses through leaks in the support hydraulics

2.11.2 Supporting ground


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The corner bearing load is stated on each support leg. This valuemust always be legible.

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The force transferred to the ground by each support leg diffusesthrough the soil in a conical pattern at an angle of 45_. Safe clear�ance to the pits and slopes must be maintained, and such clear�ance must be determined in accordance with the nature of theground. The safe clearance is measured from the bottom of the pit.

However, for undisturbed, compacted ground, the safe clearancecorresponds to pit depth, but must be a minimum of 2�m.

For loose or back−filled ground, the safe clearance is twice the pitdepth, but a minimum of 2�m.

2.11.3 Corner bearing loads


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The placing boom must not be raised until the machine has beensupported in accordance with the Operating Instructions. There isotherwise a risk of the machine toppling over.

Swing out and telescope the support legs to their end positions insequence. Intermediate positions are prohibited to guarantee sta�bility. Exceptions are machines which have been equipped by themanufacturer with a device which allows secure erection with a re�duction in support. Check the corresponding notes in this regard inthe operating instructions.

Do not carry out more than one movement at a time. If a movementis stopped, the entire volume of fluid is available for the remainingmovements, and can increase their speeds. Depending on the de�sign, it may be the case that carrying out several movements atonce (as opposed to carrying out a single movement at maximumspeed at any one time) does not bring any advantage in terms oftime. Carrying out several movements at once requires an in�creased level of attentiveness.

Lock all supports mechanically, if this is provided for in the design.Close all shut−off valves in the support hydraulics. Leaks can causethe supports to sink on one side.

2.11.4 Supports


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The machine must be made level in all directions. Provided themanufacturer does not state otherwise, the maximum permissibledeviation from the horizontal is 3_. Greater deviations from the hori�zontal overload the slewing gear for the placing boom as well as itsoverall support structure, jeopardising the stability of the machine.

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Check stability regularly during operation. The elastic distortions tothe machine frame occasionally occurring under extreme positionsof the placing boom (one support foot lifts from the ground) must becompensated for by resetting the support cylinders until all supportfeet are firmly placed on the ground.


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When preparing the machine for driving, you must perform the fol�lowing tasks in particular:− The placing boom must be folded in fully and positioned on the

placing boom support provided.− The support legs and support feet must be fully retracted and

secured.− Raised or locked axles must be lowered and released.− Accessories and moving parts belonging to the machine must be

safely stowed/secured.− The maximum permissible gross weight must not be exceeded.

While the vehicle is being driven, the delivery line, pump andhopper must be empty. If there is concrete residue in the hopper,there is a risk of injury from the concrete residue, which may bethrown out while the vehicle is in motion. This also affects the centreof gravity of the machine. Observe the road traffic regulations andspecifications of the machine manufacturer.

Maintain a distance of at least 1�m to the secured edges of the pitand a distance of at least 2�m to slopes.

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2.11.5 Driving


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Always make sure that there is sufficient clearance when drivingunder underpasses, over bridges and through tunnels or when pas�sing under overhead cables. The same minimum clearances applywhen driving under high−voltage lines as when working with theplacing boom. Be aware of the height of the truck. Only drive overarches, bridges or other supporting structures if their load−bearingcapacity is sufficient.

Do not drive across uphill or downhill gradients. Be aware of theelevated centre of gravity of the truck when travelling on a slopeand on ascending or descending routes. Always adapt your travel�ling speed to the prevailing conditions on sloping terrain.

Observe national road traffic regulations. If necessary, clean thetyres, lights and number plate. Before travelling with the machine,check that the braking, steering, signalling and lighting systems arefully functional.

Persons accompanying the driver must be seated on the passen�ger seats provided for this purpose.

Whilst the truck is in motion, the mixer drum on truck mixer concretepumps must only be rotated at the maximum speed of rotationspecified in the Operating Instructions. The truck is at risk of tippingover, particularly when travelling round corners.

The machine must only be towed, loaded and transported in ac�cordance with the Operating Instructions. Only use existing towinghitches for towing and observe the truck manufacturer’s regulations.

You must comply with the prescribed driving position, permittedspeed and itinerary when towing.

2.11.6 Towing


2��35BP03_082_2101EN

Many lifting points fitted to the machine are provided for assemblypurposes only. They are not suitable for lifting the complete ma�chine. The lifting points for lifting the entire machine are speciallymarked.

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Use only appropriate means of transport and lifting equipment ofadequate load−bearing capacity. Lifting equipment, lifting tackle,support trestles and other auxiliary equipment must be reliable andsafe in operation.

Use only stable loading ramps of adequate load−bearing capacityfor loading. Ensure that no�one is at risk from the machine tippingover or slipping.

Secure the machine on the transport vehicle to prevent it rollingaway, slipping and toppling over.

2.11.7 Loading


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2.12 Placing booms

Only raise a mobile placing boom from the driving position once themachine has been supported in accordance with the Operating In�structions. Stationary booms may only be raised after the properset−up has been checked by a subject expert.

Only raise the placing boom in the sequence described in the Op�erating Instructions. The correct sequence depends on the foldingsystem (roll−and−fold system, Z−fold system, etc.).

Do not carry out more than one movement at a time. If a movementis stopped, the entire volume of fluid is available for the remainingmovements, and can increase their speeds. Depending on the de�sign, it may be the case that carrying out several movements atonce (as opposed to carrying out a single movement at maximumspeed at any one time) does not bring any advantage in terms oftime. Carrying out several movements at once requires an in�creased level of attentiveness.

The range of a radio remote control is great enough for the machineto receive control commands (e.g. from a great distance, from in�side enclosed spaces), even without visual contact. If there is novisual contact, for example, because you are changing workplace,you must switch off the remote control. If there is no visual contact,for example, because the construction site is unclear, signallersMUST be used, and must remain in contact with the machine oper�ator using suitable means, and have visual contact with the site ofconcrete placement, work areas and danger zones, and the ma�chine.

Always ask the site management to provide you with an assistant toact as a signaller. Agree clear hand signals or other signals with thesignaller so that you can communicate with each other. You shouldposition the signaller such that he can always observe the whole ofthe placing boom. Your primary duty as the machine operator is toobserve the site of concrete placement.

2.12.1 Unfolding the placingboom


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Only slew the placing boom over persons when the delivery lineand end hose are empty. There is a risk of concrete falling out of theend hose.

Press the EMERGENCY STOP button immediately if the placingboom moves unexpectedly. If this should occur, you must ceaseworking and have the cause of the fault rectified by your qualifiedpersonnel or our After Sales Department.

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Placing booms with placing boom hinges which allow considerableflex angles have a very large potential working area. This high ma�noeuvrability means different placing booms can also be movedinto dangerous positions. Prohibited areas can be found in the Op�erating Instructions.

There is a risk that you will damage the truck, truck superstructureor obstacles on the construction site with the placing boom. Undercertain circumstances it is even possible to overload or cause dam�age to the placing boom. Uncontrolled movements may result fromthe sudden, violent release of the placing boom after collisions. Thismay also result in (possibly fatal) personal injury.

The manufacturer has indicated such impermissible working areasby the use of warning signs and information plates on the machineand appropriate notes in the Operating Instructions.


2��38 BP03_082_2101EN

The end hose must hang freely each time you start pumping, whenyou start pumping again after blockages, and during washing outprocedures. No�one should stand within the danger zone of the endhose. The diameter of the danger zone is twice the end hoselength. Do not guide the end hose when pumping is started. Thereis a risk of accident from the end hose swinging out or stones beingejected.

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If a longer end hose is used, the diameter of the danger zone isalso increased (see also page�2��13).

End hoses with a length of more than 4�m must not be guided byhand.

The end hose must not impede the movement of the placing boom;in particular, the end hose must not catch on the reinforcement orformwork. There is a risk of death if the machine topples over or theend hose shoots out on further movement of the placing boom.

2.12.2 End hose


2��39BP03_082_2101EN

Never bend the end hose over. Never attempt to straighten a bentend hose by increasing the pressure. The end hose must not besubmerged below the surface of the concrete being delivered,otherwise the concrete may spray upwards.

The concrete may also spray from the end hose due to the pres�ence of air in the delivery line. To prevent this from occurring, thehopper must be filled with concrete at least as far as the agitatorshaft so that no air can be sucked in.

The end hose must be secured against falling.

The hoseman must guide the end hose in such a way that preventsexcess spraying of concrete, and so that concrete is directed pre�cisely into the site of concrete placement.

Control the placing boom so that the hoseman can guide the endhose without power consumption. The hoseman must not carry theend hose by hand, because the weight of it may cause permanentpersonal injury.

If a drill is connected to the delivery line for the placing boom, itmust not place any further strain on the placing boom. The placingboom must be connected to the drill in such a way that the placingboom does not require adjustment. There should be 1−2 deliveryhoses between the placing boom and the drill; these must be se�cured so that they cannot move in an uncontrolled manner. If thedrill is moved on the construction site, the placing boom must notbe connected.

2.12.3 Guiding the end hoseergonomically

2.12.4 Connecting drills


2��40 BP03_082_2101EN

Return the placing boom to the driving position or rest position inthe event of storms or bad weather.− Placing booms with a vertical reach of 42�m or more may only be

operated in winds of up to wind force�7�(wind speed�51�km/h).− Placing booms with a vertical reach of less than 42�m may only

be operated in winds of up to wind force�8 (wind speed�74�km/h).

The definitive wind speed is measured at the height of the boom tip.

Wind speeds in accordance with the Beaufort scale are averagewind speeds measured over a period of 10�minutes. Higher speedgusts of wind may occur briefly during the measuring period.Higher wind speeds jeopardize the stability and safety of the struc�tural elements. There is a risk of lightning strike in a thunderstorm.

Lightning strikes pose a risk of death. The machine and the sur�rounding area will be charged with electricity. Earthing the machinedoes not reduce this risk. For this reason, you should fold in theplacing boom if there is a risk of lightning strike.

Tower cranes on construction sites generally have wind speedmeasuring equipment, enabling you to find out the wind speed atany time. If no wind speed measuring equipment is available, youcan ask the nearest meteorological office what the wind speed is, orestimate the wind speed using the following rule of thumb:− In winds of force�7 and greater, green leaves break from the trees

and there is perceptible resistance when walking against thewind.

− In winds of force�8 and greater, small branches break from treesand walking outside is significantly impeded.

The boom must not be used in temperatures below minus 15�_C(+�5�_F) unless the manufacturer has given express approval. Thereis a danger of damage to the steel (brittle�fracture) and the sealsthroughout the system at such extreme minus temperatures.

In addition, such minus temperatures should be considered therealistic lower limit for concrete placement, as it is no longer poss�ible to prepare concrete such that it can achieve its strength withoutthe use of special additives.

2.12.5 Procedure in storms

2.12.6 Concreting in coldweather


2��41BP03_082_2101EN

2.13 Delivery line systems

Only use delivery lines, end hoses, couplings, etc. which are in per�fect condition and suitable for the delivery job and have been ap�proved by the machine manufacturer. Delivery lines are subject towear which varies according to the delivery pressure, concretecomposition, the material from which the delivery line is made, etc.

If you are not responsible for the separate delivery lines, the per�missible operating pressures of these should be confirmed by theoperating company.

Delivery lines, delivery hoses, end hoses and couplings must besecurely fastened and secured to prevent spontaneous opening.

wz0066

2.13.1 Suitable delivery lines

2.13.2 Securing deliverylines


2��42 BP03_082_2101EN

Regularly force water through the delivery line under operatingpressure to check that the system is watertight.

wz0047

A properly cleaned delivery line is the best insurance against theformation of blockages. Blockages increase the risk of accidents.Never attempt to push through a blockage (e.g.�by increasing thedelivery pressure, using compressed air, etc.). There is a risk ofdeath from the delivery line bursting or from concrete being ejectedfrom the end of the delivery line.

Prevent blockages by adjusting the operating conditions. Removeblockages by reverse pumping and then restarting forward pump�ing. Repeat this process several times if necessary. If the blockageis not removed, relieve the pressure on the delivery line before re�moving the section of delivery line concerned.

2.13.3 Leak tightness andblockages


2��43BP03_082_2101EN

You must not open or tap delivery lines while these are pressurized.Concrete exiting under pressure can cause injury. The concrete col�umn must be depressurized by reverse pumping before the deliv�ery line is opened. Never work bending directly over the coupling.

wz0076

No�one should remain in the vicinity of separate delivery lines dur�ing pumping operations. Cordon off the danger zone. If it is notpossible to place a large enough cordon around the danger zone,the delivery line must be covered by suitable means.

Delivery lines, in particular riser lines which are not laid along plac�ing booms, must be securely fastened in order to transfer the forcesgenerated in them into the structure or other structural members.The lines must be laid so as to avoid kinks, sharp bends, stressesand damage during pumping operations.

2.13.4 Opening delivery lines

2.13.5 Clearance to deliverylines

2.13.6 Fastening deliverylines


2��44 BP03_082_2101EN

If a continuation delivery line is connected to the placing boom, itmust not place any further strain on the placing boom.

While you connect, use and disconnect a continuation delivery line,you must switch off the placing boom control system to preventunintended movements of the placing boom. There is a risk of acci�dent posed by jerky movements of the boom tip.

During operation, there is a risk of being crushed and of injury byshearing. Hydraulically driven devices are generally supplied withpower by the hydraulic system of a machine. It must therefore bepossible to see between the devices and the machine with the con�trol unit, and vice versa. Observe the Safety Manual for the machineand the device when connecting and operating a device. Makesure that no−one is in the danger zone before operating devices.

Only use devices that are suitable and in perfect working order toshut off, divert and clean the delivery line. Defective and unsuitabledevices may cause damage to the whole delivery system and injurepersons in the surrounding area due to a malfunction.

2.13.7 Continuation deliverylines

2.13.8 Devices for shuttingoff, diverting or clean-ing delivery lines


2��45BP03_082_2101EN

2.14 Pumping operations

The machine operator’s place of work is with the remote controlwhen the pump is in operation. If you operate the machine usingthe remote control, all operating and control devices on the ma�chine must be closed to prevent unauthorized access.

In the case of stationary placing booms, platforms or similar equip�ment are only provided for assembly and maintenance work. Use ofthese platforms as a place of work during operation is prohibited.

It is forbidden to climb onto the machine during operation. In thecase of stationary placing booms, it is forbidden to climb laddersduring operation.

Before switching on or restarting the machine or individual machinefunctions, you must ensure that doing so will not endanger anyone’ssafety.

Refrain from any procedures that may impair the stability of the ma�chine or are prejudicial to safety in any other way.

You must always carry the remote control on your person when themachine is ready for operation. Only in this way can it be guaran�teed that you can press the EMERGENCY STOP button in the eventof an emergency situation. The EMERGENCY STOP button mayonly be unlocked once the cause/emergency has been remedied.

As a general rule, you must carry the remote control so that no con�trol elements are activated unintentionally. If your attention is drawnaway from the machine (particularly when changing place of work),you must switch off the remote control.

During breaks in pumping, interruptions, maintenance work, or be�fore you leave the machine, you must secure it to prevent unin�tended movements and unauthorized use. Switch off the remotecontrol and lock it away.

2.14.1 Place of work

2.14.2 Safety

2.14.3 Remote control


2��46 BP03_082_2101EN

Keep all access covers, maintenance flaps, guards, etc. closedand locked during operation. This also applies in particular to thegrille, water box cover and covers over cylinders. There is other�wise a risk of injury from moving machine components and a risk ofburning on hot surfaces. In particular, there is a risk of burning fromthe engine, attached parts and the exhaust.

Never start work unless the grille is closed and bolted down orotherwise secured.

wz0225

Do not touch moving parts of the machine, whether the machine isrunning or switched off. Always switch off the engine first, anddump the accumulator pressure where an accumulator is fitted.

Do not insert any objects (shovel handle, trowel, etc.) into movingmachine components. Such objects could become trapped anddragged into the machine. They might then hit you or be torn fromyour hands and cause you injury.

2.14.4 Moving machine com-ponents and hot sur-faces


2��47BP03_082_2101EN

You should be constantly observing the machine for any damage orfaults while it is in use. In the event of faults or malfunctions that im�pair safety at work, shut the machine down immediately and secureit. Have the faults rectified immediately. If it is not possible to rectifyfaults which jeopardize the safe operation of the machine, you mustsuspend operations until the defects are rectified.

As the machine operator, it is your role to instruct the truck mixerdrivers who deliver the concrete to you, so that they are able to op�erate the operating elements on the concrete pump provided fortheir use. Only allow the truck mixer drivers to work alone once youare certain that they have understood your instructions.

Make sure that no−one stands between the approaching truckmixer and the machine. There is a risk of crushing between thetruck mixer and the machine.

2.14.5 Constant observationof the machine

2.14.6 Truck mixer


2��48 BP03_082_2101EN

2.15 Cleaning

You must drain the delivery line, pump and hopper completely.Concrete leavings in the hopper, in particular, may be thrown outwhilst the truck is moving.

The machine must not be driven with the placing boom unfolded orthe support legs extended, even over short distances. This rule alsoapplies when you have to drive the machine to a different site forcleaning. The placing boom and support legs must be fully re�tracted and secured.

wz0156

The preferred methods for cleaning the delivery line are reversepumping or forced cleaning with water. The agitator must beswitched on during reverse pumping. Otherwise, the concrete flow�ing back into the hopper can bend the agitator shaft. Use a catchbasket, pipe cleaning head and wash�out ball for forced cleaning toprevent any water from flowing into the formwork.

Never spray remote controls or control cabinets with barrier agents(mould oil or similar) to protect them against contamination. Thiscauses significant corrosion damage to the electrical system.

2.15.1 General


2��49BP03_082_2101EN

There is a risk of injury at all points on the machine from slipping,tripping, bumping into things, etc. Use the handles and steps toclimb into and out of the machine. It is forbidden to stand on thegrille. Do not jump from the machine.

Do not reach into the hopper or any other moving machine compo�nents. This rule must also be followed when you are opening theoutlet on the bottom of the hopper. Do not remove the grille.

Only point the water jet into the hopper or other moving machinecomponents. Do not insert the hose. It could become entangledwith moving machine components.

Take care when using aggressive cleaning agents. Aggressivecleaning agents may attack materials (e.g.�rubber) and painted sur�faces. You can use commercially available paint cleaning and careagents, as long as these have a pH�value of between�4�and�9. Askthe manufacturer of the cleaning agent to confirm its suitability. Ob�serve the manufacturer’s instructions regarding use and safe handl�ing. Wear protective clothing. Always rinse off cleaning agent thor�oughly with clean water; do not allow puddles to form.

wz0146

Do not use sea water or other water containing salt for cleaning pur�poses.

Do not use any highly flammable agent for cleaning; there is a riskof fire.

2.15.2 Cleaning agents


2��50 BP03_082_2101EN

When the delivery line is being cleaned with compressed air, thereis an increased risk of accidents caused by compressed air escap�ing explosively, spurting concrete, and delivery or end hoses mov�ing uncontrollably if they have not been removed.

Compressed air should only be used for cleaning purposes underthe supervision of a subject expert. All persons participating in thecleaning procedure must be instructed in the Safety Manual.

The manufacturer accepts no liability for damage caused by incor�rectly performed compressed air cleaning. If you blow out the deliv�ery line with compressed air, you must observe the following ruleswithout fail:− Individual pipes and short pipe runs up to 10�m in length must

not be blown through with compressed air. There is a risk of acci�dent from rebound.

− Only blow out delivery lines which have the same nominal diam�eter throughout their length. Reducer pipes must be drained andflushed out by hand.

− No bends, delivery or end hoses may be fitted at the end of thedelivery line.

− A catch basket must be fastened at the end of the delivery lineand a wash�out adaptor must be fitted on the head of the deliveryline. Catch basket and wash−out adaptor must fit the delivery linesystem.

− The concrete must be able to flow freely from the end of the deliv�ery line.

− No persons may be present in an area of 3�m around the deliveryline, at the end of the delivery line and especially in front of theopening in the catch basket.

− Care must be taken to ensure that any concrete that might be ex�pelled from the catch basket cannot injure anybody or cause anydamage.

− Separate delivery lines that are cleaned with compressed airmust be securely fastened so that they cannot move uncontrolla�bly.

− If continuing distribution systems (e.g. rotary distributors), gatevalves or other delivery line elements are connected to the deliv�ery line, they must be secured in such a way that they cannotmove in an uncontrolled manner.

2.15.3 Cleaning with com-pressed air


2��51BP03_082_2101EN

− The wash�out adaptor must be fitted with a separate, large dumpcock and a pressure gauge.

− The pressure gauge must be kept under constant observationduring the cleaning process. The pressure in the delivery linemust be rapidly dumped via the dump cock in the event of asudden drop in pressure (concrete column exiting from the endof the line) or increase in pressure (risk of blockage).

− The sponge ball or the plug used to push the concrete out mustbe sufficiently dense that the air does not pass through it into theconcrete. In addition, the delivery line must be sealed to the rearwhen the sponge ball or plug is caught in the catch basket.

− Only work on the delivery line (particularly when opening the de�livery line) if it has been depressurized. Make sure that the com�pressed air has been dumped completely.

− The dump cock must be opened in such a way that no−one canbe injured by concrete residue that might be expelled from thedump cock.

Water spraying on the machine from random directions has nodamaging effect. The electrical system is protected against spraywater, but is not waterproof.

You must close/seal all openings into which water/steam/cleaningagent must not penetrate for safety or functional reasons beforecleaning the machine with water or a steam jet (high�pressurecleaner) or other cleaning agents. Electric motors and control cabi�nets are particularly at risk.

After the machine is cleaned, the covers/tapes must be completelyremoved and the machine must be checked to ensure that it isready for operation (see�also page�2��21).

Look out for leaks, loose connections, chafe marks and damageduring the cleaning procedure. Any identified defects must be recti�fied immediately. The machine must be greased after it has beencleaned using a high�pressure cleaner.

2.15.4 Protection againstwater

2.15.5 Post–cleaning pro-cedure



General�technical�description

3��IBP02_001_0302EN

3 General technical description

This chapter describes the components and assemblies on thismachine and describes how they function. Please note that availableoptions will also be described. The machine card will tell youwhether the option described is fitted to your machine.


3��II BP02_001_0302EN


3��1AP21_114_1708EN

Below you will find an overview of the most important components;these will then be described on the following pages.

AP21_114_1708EN 1

1 2 3 4 5 6 7 8 9

1011121311 1416 15

Pos.0 Component Page

1 Documentation accompanying the machine −2 Engine −3 Exhaust after treatment system 3��954 Hydraulic pumps −5 Pressure filter 3��906 Hydraulic fluid reservoir −7 Fuel tank −8 Agitator safety cutout (RSA) 3��789 Vibrator 3��94

10 Pressure connection −11 Support leg with support foot −12 Flushing water pump 3��9213 Centralized lubrication system (optional) 3��1814 Battery −15 Support wheel −16 Towing ring −

3.1 Overview

Left–hand side


3��2 AP21_114_1708EN

Right–hand side

AP21_114_1708EN 2

1 2 3 4

678910

5

Pos.0 Component Page

1 Pressure gauge 3��902 Output controller 3��863 OPS/SPC control cabinet 3��214 Magnetic switch distributor casing 3��805 Cable remote control 3��746 Machine rating plate 3��77 Buzzer −8 Fuse box 3��69

Pump control system 3��88

9 Drive cylinder emergency operation 3��88Emergency operation � transfer tube 3��88

10 Centralized lubrication system 3��18


3��3AP02_330_0904EN

This illustration shows examples of safety equipment which may befitted on the machine.

AP02_330_0904EN 1

1 2 3 4 5

67910111213 8

No. 0 Safety equipment

1 EMERGENCY STOP button / STOP button on the remote control2 Covers over the switch cylinders3 Side protection doors4 Exhaust guard5 Safety grille on the V−belt6 Transport protection7 Securing bolts/spring pins on the support leg8 Hydraulic/mechanical set−up foot9 Water box cover

10 Toggle switch for Local control − 0 − Remote control11 EMERGENCY STOP button on the operator’s side12 Engine stop13 Agitator safety cutout

→

3.2 Safety equipment


3��4 AP02_330_0904EN

AP02_330_0904EN 2

14

15

16

Continued

No. Safety equipment

14 Sound proofing equipment/sound proofing kit15 Spray guard16 Grille on the hopper

DangerNever operate the machine if the safety equipment is not working.You�could injure yourself or others or damage the machine.

Check the safety equipment as described in the Operating Instructions.


3��5AP02_999_1501EN

You will find the most important technical data and setting values foryour machine in the following table, and also in the test reading de�livered with your machine and on its rating plate.

BSA model 1407 D

Height 2510 mm

Dimensions Length 5750 mm

Width 2020 mm

Performance data

Main pump hydraulic fluid pressure 350 bar

Maximum concrete pressure − rod�side 71 bar

Maximum concrete pressure − piston�side 106 bar

Maximum output − rod�side 71 m3/h

Maximum output − piston�side 47 m3/h

Min./max. theoretical strokes under no load − rod�side 27 1/min

Min./max. theoretical strokes under no load − piston�side 18 1/min

Control voltage 12 V

Settings

Hydraulic fluid cut−out temperature 90 _�C�

Capacities

Hydraulic fluid reservoir 60 litres

Fuel tank 120 litres

3.3 Technical data


3��6 AP21_056_1604EN

The machine in question meets the requirements set out in Appendix1 of Directive 2014/30/EU of the European Parliament and of theCouncil of 26 February 2014.

The electromagnetic compatibility has been tested and meets therequirements set out under EN 13309:2010−12.Test report number: P150760The machine can be used in residential areas without restriction.

3.3.1 Electromagneticcompatibility (EMC)


3��7BP22_830_1005EN

The following rating plate is attached to the machine:

BP22_830_1005EN 1

Betonpumpe

BSA 1407 D5

214490278

1

2

3

4

5

6

7 8

No. 0 Designation

1 Designation of the machine2 Machine model3 Machine number4 Maximum fluid pressure in the hydraulic system [bar]5 Year of manufacture6 Maximum delivery pressure [bar]

The following data depend on the machine model7 Total weight [kg]8 Delivery line diameter [mm]

NoteIf specific details do not apply to a machine, the relevant fields areblank. With truck�mounted concrete pumps, the weight specifiedby�the vehicle manufacture applies as per 76/114/EEC: "Official permitted total weight specified by manufacturer".

3.3.2 Machine rating plate


3��8 BP21_359_1001EN

The sound pressure level produced by the machine is given below inaccordance with Directive 2006/42/EU.

The place of work is from the remote control. The machine has asound pressure level of 85 dB(A) within a radius of 16�m. Ear de�fenders must be worn in the vicinity of the machine since the soundpressure level can be higher. The sound pressure was determinedon the basis of Directive 2000/14/EU.

The sound power level produced by the machine is given below inaccordance with Directive 2000/14/EU.

The plate illustrated below, which shows the measured sound powerlevel of the machine, is located near the machine’s rating plate.

BP21_359_1001EN 1

116No. 0 Designation

LWA Sound power leveldB Value in decibels

3.3.3 Sound pressure level

3.3.4 Sound power level


3��9BP21_359_1001EN

A uniform method of measuring the noise generated by a machine(Directive 2000/14/EU) has been applicable throughout Europe since1�January 2002.

In the past, the sound pressure level of the machine was stated. Tomeasure this level, the sound produced by the machine wasmeasured at several measuring points and at a fixed distance andheight. The average value was determined from these measure�ments and converted to a theoretical distance. The sound pressurelevel stated for the machine therefore always referred to a theoreticaldistance and was given in dB(A).

Disadvantage: the actual sound pressure level is higher if you standcloser to the machine.

Nowadays, the sound power level of the machine is stated. To calcu�late this, an imaginary sphere of defined diameter is centered on themachine. The sound pressure level is measured again at severalmeasuring points on this sphere. To obtain the value for the soundpower level, the calculated sound pressure level is now multiplied bythe surface area of the imaginary sphere. The sound power level isgiven in dB.

Advantage: as you approach the machine, although the sound pres�sure level increases, the surface area of the imaginary sphere de�creases. This means that multiplying the two figures gives the samesound power level as before.

What does this mean?

Sound pressure level

Sound power level


3��10 AP02_004_1211EN

This chapter is intended to help you understand the operationalsequences of the machine so that you can limit the field of themachine’s applications to suitable areas and avoid errors inoperation.

Your machine may be mounted on different chassis models or ona�static base structure, depending on the equipment. The chassismodel is stated on the machine card and the maximum permittedspeed is stated on the rating plate.

Your machine can be towed by a tractor unit if fitted with anF�8�chassis. The chassis is unbraked and is designed for a maxi�mum speed of 8�km/h only. The machine may therefore only betowed by a tractor unit on the construction site.

NoteThe machine is neither equipped nor approved for travel on publicroads.

Your machine can be towed by a tractor unit if fitted with anF�25�chassis. The chassis is unbraked and is designed for a maxi�mum speed of 25�km/h only. The machine may therefore only betowed by a tractor unit on the construction site.

NoteThe machine is neither equipped nor approved for travel on publicroads.

3.4 Description of thefunctions

3.4.1 Chassis

F 8 chassis

F 25 chassis


3��11AP02_004_1211EN

The machine may travel on public highways in the same way as astandard trailer if fitted with an F�80 chassis.

NoteTrailer concrete pumps may only use public roads if properlyapproved.

Your machine can be towed by a tractor unit if fitted with a crawlertrack.

NoteObserve the manufacturer’s operating and maintenance instructions.

The machine is neither equipped nor approved for travel on publicroads.

If your machine is fitted with a stationary base structure, it can onlybe moved to the construction site on a transport vehicle.

The support legs give the stability required. They are manuallyadjustable.

F 80 chassis

Crawler track

3.4.2 Static base structure

3.4.3 Support legs


3��12 AP02_004_1211EN

6

5

4

3

2

1

7

AP02_004_1211EN 1

No.0 Designation

1 Piston rod

2 Water box

3 Delivery piston

4 Delivery cylinder

5 S transfer tube

6 Pressure connection

7 Delivery line

Putzmeister pumps are driven hydraulically by diesel engines orelectric motors acting through fluid pumps. The delivery pistons�(3)are connected to the piston rods�(1) of the drive cylinders by way ofintermediate flanges. The drive cylinders are extended and retractedhydraulically and thus push the delivery pistons�(3) forwards andbackwards in the delivery cylinder�(4). The drive cylinders arehydraulically coupled together so that they run in counter stroke.

3.4.4 Pump


3��13AP02_004_1211EN

The S�transfer tube�(5) is built into the hopper on the pump. Its wearring locates against the spectacle wear plate. Its other end is fitted inthe pressure connection�(6) to which the delivery line is connected.The transfer tube�(5) is switched across by two switch cylinders.

The water box�(2) is fitted between the drive cylinders and thedelivery cylinders. The water in the water box performs the followingfunctions:− it cools the delivery pistons and the piston rods;− it rinses the inner wall of the delivery cylinders.

The returning delivery piston sucks the medium in from the hopper.At the same time, the advancing delivery piston forces the mediumwhich has previously been sucked in through the transfer tube intothe delivery line.

At the end of the stroke, the pump switches over, i.e. the transfertube is swung in front of the full delivery cylinder and the deliverypistons reverse their direction of movement.

Reversal of the delivery pistons’ direction in the middle of the strokemovement. The transfer tube switches over. The medium is stillpumped without interruption. Changing the stroke over helps preventthe formation of a blockage.

The delivery pistons reverse their direction during the stroke move�ment for reverse pumping. The transfer tube does not switch over sothe pump now runs in reverse. The medium is sucked from the deliv�ery line and pumped back into the hopper and the pressure in thedelivery line is dumped.

S transfer tube

Water box

Pumping

Change-over

Reverse pumping


3��14 AP02_055_9710EN

The hopper is equipped with a hydraulically driven agitator. Theagitator performs two functions:− it improves the filling rate of the delivery cylinders;− it mixes the concrete.

1

2

3

AP02_055_9710EN 1

No0 Designation

1 Hydraulic motor2 Agitator shaft3 Agitator helix

The filling rate in the delivery cylinders should be as high as possiblewhen pumping. This is achieved by having the agitator helix mix to�wards the delivery cylinders.

The concrete should be mixed following reverse pumping from thedelivery line into the hopper. This is achieved by having the agitatorhelix mix away from the delivery cylinders.

3.4.5 Agitator

Improving thefilling rate

Mixing the concrete


3��15BP22_827_1212EN

General conditions are control values, which are partly given asphysical conditions and which set limits for using a concrete pump.The following general conditions must be observed when using aconcrete pump.

If operated, maintained and inspected correctly, and if original orequivalent spare parts and accessory components are used, theservice life is 15�years.

Truck-mounted concrete pump standard

Output [m3]/year 30000

Operating hours [h]/year 400

Uses per day 3

Uses per year 750

Truck mixer concrete pump standard



Uses per day 1

Uses per year 250

stationary concrete pumpStationary boom

Delivery line valve

standard



Uses per day 1

Uses per year 250

3.5 General conditionsfor using a concretepump

3.5.1 Service life


3��16 BP22_827_1212EN

A concrete pump is designed for industrial use on outdoor construc�tion sites, or indoors with adequate ventilation. It must not be used inareas where there is a potentially explosive atmosphere.

Putzmeister must be contacted if the concrete pump is to be used ata height greater than that given here. The standard reference level isthe European standard elevation zero (NHN).

Pump type maximum heightof job

Piston pump with internal combustionengine,Delivery line valve

2500�m

Piston pump with electric motor, 1000�m (��40�°C)p p ,Stationary boom 2000�m (��30�°C)

Rotor pump 2000�m

3.5.2 Site of use

3.5.3 Height of job


3��17BP22_827_1212EN

Putzmeister must be contacted if the concrete pump is to be usedoutside the given temperature ranges.

Machine model min [° C]max[° C]

Truck−mounted concrete pump,Delivery line valve

15 + 50Truck mixer concrete pump (with piston pump)

−�15 +�50

Stationary concrete pump with dieselengine�*

−�8 +�45

Stationary concrete pump with electricmotor�**Stationary boom�**

−�8 +�40

General rotor pump�*** +�3 +�40

*�Limited due to the diesel engine without pre�heating device. Whenusing below −8�°C, a pre�heating device must be installed.**�Limited due to supply cable during overload. Temperature rangescan be extended if special measures are applied.***�Limited due to the vacuum pump and rotor hose.

3.5.4 Operatingtemperature


3��18 AP02_908_1304EN

The centralized lubrication system comprises a lubricant pump /grease gun, lubricant distributors, relief valves and supply lines.

AP02_908_1304EN 1

1a

3

5

1b

2

3

44

77 9

6

8

No. 0 Designation

1a Lubricant reservoir1b Lubricant pump2 Grease gun3 Lubricant distributor4 Agitator shaft bearings5 Transfer tube bearing6 Upper switch cylinder bearings7 Lower switch cylinder bearings8 Switching shaft bearings

3.5.5 Centralized lubrica-tion system


3��19AP02_908_1304EN

The centralized lubrication system supplies grease to the lubricationpoints connected to it. The lubrication points are lubricated in fixedcycles.

The lubricant reservoir may be filled up to the �Max"�marking throughthe filling nipple or from above through the filling opening.

NoteNote the following when filling the lubricant reservoir:� Use only a grease listed in the lubricant recommendation table.� Never fill the reservoir above the MAX�mark.� Never pump the reservoir dry.� Switch off the power supply before filling the reservoir from above.

The grease gun can be used to manually distribute grease to the lu�brication points.

Lubricant reservoir

Grease gun


3��20 AP02_057_9801EN

The electrical control devices and operating elements on thismachine are described on the following pages. The summary at thestart of this chapter will show you where the various control devicesare located on the machine. The symbols used on the electrical con�trol devices are described in one of the preceding sections.

The electrical control devices may include the following components,depending on the equipment on your machine.− control cabinet− cable remote control− radio remote control− distributor casing for magnetic switch

NoteFurther control devices and components are described in the�Hydraulic control devices" (from page 3��85) and �Othercomponents" (from page 3��91) sections.

3.6 Electrical controldevices


3��21AP21_022_1704EN

You can control the functions of the machine from the control cabi�net.SPC = Small Pump ControlThe SPC display enables you to determine the operating state of themachine.Use the operating elements of the SPC display unit to navigate withinthe menu structure and apply settings.Some of the control and operating elements illustrated below maynot be present on your machine. The hole is closed with a blankingplug if a control or operating element is omitted.

AP21_022_1704EN 1

1 2

3

4

567891011

Pos. 0Operating/control element

Meaning/function Comments

1 Button EMERGENCY STOP2 SPC display unit Displaying and setting operating states3 Toggle switch Increase � reduce engine speed4 Rotary controller Increase � reduce output optional5 Toggle switch Support leg control optional

→

3.6.1 Control cabinet withSPC display unit

Front view


3��22 AP21_022_1704EN

Continued



6 Toggle switch Deactivate EMERGENCY STOP − 0 − Ac�knowledge agitator/agitator safety cutout(RSA)

7 Ignition−starter switch Diesel engine On − Off8 Toggle switch Open shut�off valve − agitator − close

shut�off valve9 Toggle switch Agitator on � forward pumping

Agitator offAgitator on � reverse pumping

10 Toggle switch Pump off − 0 − Vibrator on11 Toggle switch Forward pumping�− 0�− Reverse pumping


3��23AP21_022_1704EN

AP21_022_1704EN 2

1

2



1 Round socket, 4 pin Connection for vibrator optional2 Bush Connection for remote control/

Local control − Remote controlLocal control = replacement plug isplugged in

Right–hand view


3��24 AP21_022_1704EN

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AP21_022_1704EN 3

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Meaning/function

1 SPC displayMenu−driven operating states and adjustable functionsare displayed in the SPC display.

2 Button Function button for navigation and operation.3 System LED The LED of the display unit lights up when the control

cabinet is supplied with power and flashes when theprogram is running.

4 Button Function button for acknowledging5 Direction key Function button for navigation and operation.6 Button Function button with no function

SPC display unit andoperating elements


3��25AP21_022_1704EN

Special features of the control cabinet

If you have pressed the EMERGENCY STOP button, you may onlystart the pump up again as described below:− Unlock the EMERGENCY STOP button by turning it.− Actuate �Deactivate EMERGENCY STOP" toggle switch,− Switch the pump on again using the �Forward pumping � 0 � Re�

verse pumping" toggle switch.

The control system can control machines with an open hydraulic cir�cuit. The open hydraulic circuit is called Open Pump System (OPS).

For diesel engines with an electronic engine governor (EMR), theSPC display unit can partly replace the control unit of the enginemanufacturer.

NoteYou can switch on the SPC display unit with the �ignition−starterswitch" on the control cabinet.

Starting up the pumpafter EMERGENCYSTOP

Control system (OPS)

SPC display


3��26 AP21_022_1704EN

The function of the �Forward pumping � 0 � Reverse pumping"toggle switch depends on the local or remote control.− The replacement plug is plugged in for local control. The pump

can be switched over using the �Forward pumping � 0 �Reversepumping" toggle switch on the control cabinet.

− The pump can only be switched over on the cable or radio remotecontrol using the �Pump on � 0 � Reverse pumping" toggle switchfor remote control.

The EMERGENCY STOP circuit is activated automatically when youremove the replacement plug (remote control). You must press the�Deactivate EMERGENCY STOP" toggle switch to deactivate theEMERGENCY STOP circuit.

If the agitator safety cutout has been triggered, it must be acknowl�edged using the �Deactivate EMERGENCY STOP � 0 � Acknowledgeagitator/agitator safety cutout (RSA)" toggle switch so that the agita�tor starts running again.

You must always lock the control cabinet and store the key in a safeplace to ensure that unauthorised persons cannot operate the con�trol system.

Forward pumping�− 0�−Reverse pumping

Switchover from local toremote control

Acknowledge agitator

Locking


3��27AP21_024_1511EN

The SPC display unit on the control cabinet has a graphical displayand operating elements. The SPC display enables you to determinethe operating state of the machine. Use the operating elements ofthe SPC display unit to navigate within the menu structure and applysettings.

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Meaning/function

1 SPC displayMenu−driven operating states and adjustable functionsare displayed in the SPC display.

2 Button Function button for navigation and operation.3 System LED The LED of the display unit lights up when the control

cabinet is supplied with power and flashes when theprogram is running.

4 Button Function button for acknowledging5 Direction key Function button for navigation and operation.6 Button Function button with no function

3.6.2 SPC display unit

SPC display unit andoperating elements


3��28 AP21_024_1511EN

The symbols used in the SPC display appear differently dependingon the meaning.

Colour / Appearance Meaning

Background colours:

Black Standard appearance

Symbol colours:

White Function is selected (switch or buttonpressed)

Green Function is active

Yellow Warning on the engine’s control dis�play:Limit reached

Red

Warning on the engine’s control dis�play:FaultThe fault must be remedied beforethe operation can be restarted on themachine.

Dark grey Display of inactive functions

Input field appearance:

Green Display of input fieldsSet setpoint value = actual value inthe controller− Input is possible depending on themenu

Yellow

Value has been changed, but has notyet been acknowledged with the�OK" button− Input is possible depending on themenu

Appearance of thesymbols


3��29AP21_097_1703EN

The following pages show the password�free section of the menustructure (example). A start screen is always displayed when the ma�chine is started up.

AP21_097_1703EN 1

12

3 4 5 6

7 8

Menu structure


3��30 AP21_097_1703EN

Pos.0 Display Function/meaningSeepage

1 HOMEThe HOME menu is the main menu. Data andmain instruments are displayed here.

3��31

2 Expanded HOMESelect this menu to display data and all in�struments.

3��49

3 Software informationSelect this menu to display the software ver�sion and firmware version.

3��52

4 Operating data Select this menu to display operating data. 3��53

5 Fault memorySelect this menu to display the fault codesfor the engine.

3��55

6 User settingsSelect this menu to set parameters such asthe delivery rate and stroke time.

3��56

7 Lubrication

Select this menu to begin a manual lubrica�tion cycle and display parameters such asthe number of strokes until the next lubrica�tion.

3��60

8 Inputs and outputsSelect this menu to display the number ofactive inputs and outputs.

3��63


3��31AP21_098_1703EN

The HOME menu is the main menu. Data and main instruments aredisplayed here.

Function buttons in the HOME menu

1 2 3 4 5 6AP21_098_1703EN 1

Pos.0 Display Function/meaning

1 ButtonThe last selected start menu is opened by pressingbutton�(1).

2 ButtonThe expanded HOME menu is opened by pressingbutton�(2) in the HOME menu.

3 Direction keySubmenus are selected by pressing on the left or rightof the direction button�(3).

4 ButtonThe selected submenu is acknowledged and thencalled up by pressing button�(4).

5 ButtonThe �EOC" is switched on/off by pressing button�(5) inthe HOME menu.

6 ButtonThe �S transfer tube switch−over" function is switchedover by pressing button�(6) in the HOME menu.

HOME menu


3��32 AP21_098_1703EN

All symbols in the menu bar

2 4 53

AP21_098_1703EN 2

1

Pos.0 Symbol Function/meaning

1

Back to the start menuThis symbol is displayed regardless of the currentmenu.The symbol has no function in the HOME menu.

2 Menu: Expanded HOME

Submenu: Software information

Submenu: Operating data

Submenu: Engine fault code

3 Submenu: User settings

Submenu: Lubrication

Submenu: Inputs and outputs

Submenu: ServicePassword−protected service area

→


3��33AP21_098_1703EN

Continued

4 Switch EOC on/off

5S transfer tube switch−over:Soft, hard and auto

6Reset the �trip" day counterThis symbol is displayed in the following menus:Operating data, user settings


3��34 AP21_098_1703EN

Instruments in the HOME menu

1

AP21_098_1703EN 3

2 3


1Cooling water tempera�ture�[°C],analogue and digital

The cooling water temperature is displayed.

2Engine speed�[rpm],analogue and digital

The engine speed is displayed.

3Hydraulic fluid tempera�ture�[°C],analogue and digital

The hydraulic fluid temperature is displayed.


3��35AP21_099_1703EN

Symbols in the HOME menu

AP21_099_1703EN 1

NoteDepending on the equipment fitted to your machine, some of thefunctions illustrated may not be present. The symbol is not lit if afunction is not present.


3��36 AP21_099_1703EN

NoteThe warning strategy of the exhaust after treatment system complieswith the relevant national codes of practice.The following emissions−relevant faults are therefore displayed:� Fill level of the DEF container� DEF quality, DEF manipulation, DEF hardware� DPF regeneration, DPF crystallisation


3��37AP21_099_1703EN

Warning triangle deactivatedSymbol is shown in grey, as long as the escalation stages have notyet been reached on the exhaust after treatment system.

Warning triangle, yellowSymbol lights up yellow in the following cases:

− Once the tank content is between <�10% and >�5%,− If a DPF regeneration is required or if regeneration is running− If DPF crystallisation is shown,− If DPF regeneration is required and shows escalation stage�1,− If the DPF soot load >�100%− If DEF quality, DEF manipulation, DEF hardware are poor.− If DEF quality, DEF manipulation and exhaust gas treatment are

inadequate.Power reduction stage 1: The engine torque is reduced by 25% (seethe engine manufacturer’s documentation).

Warning triangle, redSymbol lights up red in the following cases:

− Once the tank content is between <�5% and 0%,− If the DPF soot load >�125%,− If DPF crystallisation is shown,− If DPF filter maintenance is required and shows escalation stage�2,− If DEF quality, DEF manipulation, DEF hardware are insufficient.Power reduction stage 2: The engine torque is reduced by 50% andthe rated speed by 60% (see engine manufacturer’s documentation).


3��38 AP21_099_1703EN

Engine oil pressureThis symbol is displayed in grey if the engine oil pressure is withinthe specified range.This symbol flashes and is displayed in red if the engine oil pressureis too low.If the signal for the engine oil pressure is interrupted for longer than afew seconds, the concrete pump is switched off.

Engine oil temperatureThis symbol is displayed in grey if the engine oil temperature iswithin the specified temperature range (see the engine manufac�turer’s documentation).This symbol flashes and is displayed in red if the engine oil tempera�ture specified by the engine manufacturer is exceeded.If the signal for the engine oil temperature is interrupted for longerthan a few seconds, the concrete pump is switched�off.

Fuel filterThis symbol is displayed in grey if the fuel filter is not clogged.This symbol flashes and is displayed in yellow if a fault has occurredin the fuel filter or if the fuel filter is clogged.

Coolant levelThis symbol is displayed in grey if the engine coolant level is withinthe specified range.This symbol flashes and is displayed in red if a fault has occurred inthe coolant reservoir or if the engine coolant level is too low.

CAN bus engine communication CAN1This symbol is displayed in grey if no fault has occurred in the CANbus 1.This symbol flashes and is displayed in red if a fault has occurred inthe CAN bus (CAN1 = connection between controller and display).You need to have the fault rectified by a Putzmeister service techni�cian.


3��39AP21_099_1703EN

CAN bus engine communication CAN2This symbol is displayed in grey if no fault has occurred in the CANbus 2.This symbol flashes and is displayed in red if a fault has occurred inthe CAN bus (CAN2 = connection between engine control unit andcontroller). You need to have the fault rectified by a Putzmeister ser�vice technician.

SensorsThis symbol is displayed in grey if no fault has occurred in the mag�netic switches (see the �magnetic switch distributor casing" section)or in the resolver on the switching shaft.This symbol flashes and is displayed in red if a fault has occurred ina magnetic switch or resolver. You need to have the fault rectified bya Putzmeister service technician.

Hydraulic fluid overheatingThis symbol is displayed in grey if the temperature sensor in the leakoil line of the main hydraulic pump measures a temperature lowerthan 85�°C and no fault has occurred.This symbol flashes and is displayed in red if the temperature sensorin the leak oil line of the main hydraulic pump measures a tempera�ture of 85�°C or higher or a fault has occurred.If the fluid overheats to a temperature of above 90�_C, the pump willbe switched off automatically.

Battery charging controlThis symbol is displayed in grey if the battery is charged.This symbol flashes and is displayed in red if the battery voltage hastripped out and the engine is switched off.


3��40 AP21_099_1703EN

EMERGENCY STOPThis symbol is displayed in grey if no EMERGENCY STOP button hasbeen pressed or if the EMERGENCY STOP has been acknowledged.This symbol flashes and is displayed in red if an EMERGENCY STOPbutton has been pressed.

Agitator safety cutout (RSA)This symbol is displayed in grey if the agitator safety cutout has notbeen pressed or if the agitator safety cutout has been acknowl�edged.This symbol flashes and is displayed in red if the agitator safety cut�out has been activated.

Pump statusThis symbol is displayed in grey if the concrete pump is switched offand all pump functions (�Pump on", �Forward pumping" and �Re�verse pumping") either have not been operated or have been ac�knowledged.This symbol is displayed in white if the concrete pump is switched off(when the �Pump off � 0 � Vibrator on" toggle switch has beenmoved to the �Pump off" switch position on the control cabinet).

Forward pumpingThis symbol is displayed in white if the concrete pump is switched offand the �Forward pumping" pump function is operated.Symbol lights up green if the concrete pump is switched on and the�Forward pumping" pump function is operated.

Reverse pumpingThis symbol is displayed in white if the concrete pump is switched offand the �Reverse pumping" pump function is operated.Symbol lights up green if the concrete pump is switched on and the�Reverse pumping" pump function is operated.


3��41AP21_099_1703EN

EOCThis symbol is displayed in grey if EOC is switched off.Symbol lights up green if EOC is switched on.

Delivery rateThis symbol is displayed in grey if the concrete pump is switched off.The delivery rate is displayed in numbers if the concrete pump isswitched on and the �Forward pumping" pump function is operated.

S transfer tube switch–overThe �S transfer tube switch−over" function can be switched over asfollows using the button (see the �Function buttons in the HOMEmenu" section):− The S transfer tube switch−over is carried out with less force:

�Soft".− The S transfer tube switch−over is carried out with more force:

�Hard".− The S transfer tube switch−over is adjusted automatically: �Auto" =

factory settings after restart.


3��42 AP21_099_1703EN

VibratorThis symbol is displayed in grey if the vibrator is switched off.This symbol is displayed in white if the concrete pump and the vi�brator are switched off but the �Pump off � 0 � Vibrator on" toggleswitch has been switched to �Vibrator on" on the control cabinet withSPC display.Symbol lights up green if the vibrator is switched on.

LubricationThis symbol is displayed in grey if no lubrication procedure has beenactivated.This symbol lights up green during the lubrication procedure.This symbol lights up red if there is a fault or if a lubricant reservoir isempty.

Power reductionThis symbol is shown in grey, as long as the escalation stages withpower reduction have not yet been reached on the exhaust aftertreatment system.This symbol is shown in yellow if the escalation stages with powerreduction have been reached on the exhaust after treatment system.


3��43AP21_099_1703EN

Fill level warning symbol for the DEF container (green)This symbol lights up green if the container content is between<�12% and >�10%.

Fill level warning symbol for the DEF container (yellow)This symbol lights up yellow if the container content is between<�10% and >�5%.

Fill level warning symbol for the DEF container (orange)This symbol lights up orange if the container content is between<�5% and >�2.5%. Power reduction stage 1 is activated.

Fill level warning symbol for the DEF container (red)This symbol lights up red if the container content is between <�2.5%and 0%. Power reduction stage 2 is activated.

CautionDamage to the exhaust after treatment system if the diesel exhaustfluid (DEF) quality does not comply with the specifications ofISO�22241.If the DEF quality deteriorates, the complete engine system cannotcomply with the permitted exhaust gas values.Do not dilute the DEF, as this will cause damage to the SCR system.Do not fill the DEF container with diesel fuel, as this will cause dam�age to the SCR catalytic converter.Use only the specified DEF−quality products.Observe the �DEF quality warning symbols" in the display. These aredisplayed as soon as sub−standard DEF quality or a manipulated ordefective component has been detected.


3��44 AP21_099_1703EN

Warning symbol for DEF quality and exhaust gas treatment(grey)This symbol lights up grey if the DEF quality and exhaust gas treat�ment are good.

Warning symbol for DEF quality and exhaust gas treatment(green)This symbol lights up green if the DEF quality and exhaust gas treat�ment are good.The DEF container content is between <�12% and >�10%.

Warning symbol for DEF quality and exhaust gas treatment (yel-low)Symbol lights up yellow if the DEF quality and exhaust gas treatmentare poor.The DEF container content is between <�10% and >�5%.

Warning symbol for DEF quality and exhaust gas treatment(orange)Symbol lights up orange if the DEF quality and exhaust gas treat�ment are inadequate. Power reduction stage 1 is activated.The DEF container content is between <�5% and >�2.5%.

Warning symbol for DEF quality and exhaust gas treatment (red)Symbol lights up red if the DEF quality and exhaust gas treatmentare insufficient. Power reduction stage 2 is activated.The DEF container content is between <�2.5% and 0%.


3��45AP21_099_1703EN

Warning symbol for DEF qualityAbbreviations used:�Q" = Quality�M" = Manipulation�H" = Hardware = components in the exhaust after treatment system�C" = Crystallisation

DEF qualitySymbol lights up green if the DEF quality and exhaust gas treatmentare good.Symbol lights up yellow if the DEF quality and exhaust gas treatmentare poor.Symbol lights up orange if the DEF quality and exhaust gas treat�ment are inadequate. Power reduction stage 1 is activated.Symbol lights up red if the DEF quality and exhaust gas treatmentare insufficient. Power reduction stage 2 is activated.

DEF manipulationSymbol lights up green if no manipulation has been detected andthe exhaust gas treatment is good.Symbol lights up yellow if manipulation has been detected and theexhaust gas treatment is poor.Symbol lights up orange if manipulation has been detected and theexhaust gas treatment is inadequate. Power reduction stage 1 isactivated.Symbol lights up red if manipulation has been detected and the ex�haust gas treatment is insufficient. Power reduction stage 2 is acti�vated.

DEF hardwareSymbol lights up green if no defective component has been de�tected and the exhaust gas treatment is good.Symbol lights up yellow if a defective component has been detectedand the exhaust gas treatment is poor.Symbol lights up orange if a defective component has been de�tected and the exhaust gas treatment is inadequate. Power reductionstage 1 is activated.Symbol lights up red if a defective component has been detectedand the exhaust gas treatment is insufficient. Power reduction stage2 is activated.


3��46 AP21_099_1703EN

NoteCrystallisation is monitored by the SCR system.As soon as crystallisation is detected, you must implement counter�measures by selecting the operating modes (Heat mode or stand�still).

DEF crystallisationSymbol lights up green if no crystallisation is detected and passiveDPF regeneration (heat mode) takes place during engine operation.Symbol lights up yellow if crystallisation has been detected and ac�tive standstill DPF regeneration is required. Active regeneration mustbe initiated manually by the machine operator.Symbol lights up orange if crystallisation has been detected and ac�tive DPF regeneration is urgently required. Active regeneration mustbe initiated manually by the machine operator. Power reductionstage 1 is activated.Symbol lights up red if crystallisation has been detected. Active DPFregeneration is initiated by DEUTZ After Sales department. Powerreduction stage 2 is activated.If the DPF regeneration warning symbol lights up red, then DPF filtermaintenance is also required.


3��47AP21_099_1703EN

Warning symbol for DPF regeneration (grey)Symbol lights up grey when DPF regeneration is not required.

Warning symbol for DPF regeneration (green)Symbol lights up green and passive DPF regeneration (heat mode)takes place during engine operation.

Warning symbol: DPF regeneration (yellow)Symbol lights up yellow if active standstill DPF regeneration is re�quired. Active regeneration must be initiated manually by the ma�chine operator.

Warning symbol: DPF regeneration (orange)Symbol lights up orange if active DPF regeneration is urgently re�quired. It indicates escalation stage�1. Active regeneration must beinitiated manually by the machine operator. Power reduction stage 1is activated.If the engine continues to be operated without the required activeregeneration, this activates power reduction stage�2. Active DPF re�generation is initiated by DEUTZ After Sales department (SERDIAservice tool required, see engine manufacturer’s documentation).

Warning symbol: DPF regeneration (red)Symbol lights up red if DPF filter maintenance is required and indi�cates escalation stage�2. Filter is changed by DEUTZ After Sales de�partment.

Warning symbol: DPF regeneration complete (green)Symbol lights up green if DPF regeneration is complete.

Warning symbol: DPF regeneration running (yellow)Symbol lights up yellow if DPF regeneration is running. The thermom�eter symbol warns of extremely high exhaust gas temperatures(>�600 °C) that can arise during the stationary regeneration pro�cedure.


3��48 AP21_099_1703EN

NoteThe engine oil must be changed every 500 hours or after the DPFhas been regenerated several times, and if the warning symbol �En�gine oil change required" is displayed.

Warning symbol for engine oil change required (yellow)Symbol lights up yellow if the engine oil needs to be changed.

Warning symbol for DPF soot filter (grey)This symbol is displayed in grey if the DPF soot filter is not loadedwith soot (DPF soot load <�62%).

Warning symbol for DPF soot filter (yellow)This symbol is displayed in yellow if the DPF soot filter is loaded withsoot (DPF soot load >�62%).

Warning symbol for DPF soot filter change (red)This symbol is displayed in red if the DPF soot filter is loaded withsoot (DPF soot load >�100%) and the soot filter therefore needs to bechanged.


3��49AP21_100_1703EN

The �Expanded HOME" menu is an expanded display of the HOMEmain menu. Data and additional instruments are displayed here.

Function buttons in the expanded HOME menu

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2 ButtonThe HOME menu is opened by pressing button�(2) inthe �Expanded HOME" menu.

3 Direction keySubmenus are selected by pressing on the left or rightof the direction button�(3).

4 ButtonThe selected submenu is acknowledged and thencalled up by pressing button�(4).


6 ButtonThe �S transfer tube switch−over" function is switchedover by pressing button�(6) in the HOME menu.

Expanded HOMEmenu


3��50 AP21_100_1703EN

Instruments in the expanded HOME menu

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AP21_100_1703EN 2

2 3 4

5 6 7


1Cooling water tempera�ture�[°C], analogue

The cooling water temperature is displayed.

2Engine oil pressure�[bar],analogue

The engine oil pressure is displayed.

3Engine speed�[rpm], ana�logue and digital

The engine speed is displayed.

4Hydraulic fluid tempera�ture�[°C], analogue

The hydraulic fluid temperature is displayed.

5Fuel consumption�[l/h],analogue

The fuel consumption is displayed.

6 Torque�[N/m], analogue The current torque is displayed.

7Battery voltage�[V], ana�logue

The current battery voltage is displayed.


3��51AP21_100_1703EN


NoteYou can find a description of all symbols in the menu bar, regardlessof the current menu, in the section �All symbols in the menu bar".

Symbols in the expanded HOME menu

AP21_100_1703EN 3

NoteYou can find a description of the symbols in the expanded HOMEmenu in the section �Symbols in the HOME menu".


3��52 AP21_030_1511EN

In this menu, you can read off the software versions of the controlsystems.

Display Function/meaning

PM PutzmeisterSPC Small Pump Controlg2 Generation 2C ControllerD DisplayV100 Version 1.0.0

1

AP21_030_1511EN 1

2


1 Software versionsThe software versions of the control systems are dis�played.

2 Momentary�contact switchThe last selected HOME menu can be opened bypressing button�(2).

Software information


3��53AP21_031_1703EN

The operating data for the machine are displayed in two tables inthis menu, with the total values in the �total" table on the left and thecurrent values in the �trip" table on the right.

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1 �Total" table The total values for the operating data are displayed.

2 �Trip" tableThe current values for the operating data are dis�played.

3 ButtonThe current values in the �trip" table are reset after afew seconds by pressing button�(3).

4 ButtonThe last selected HOME menu can be opened bypressing button�(4).

→

Operating data


3��54 AP21_031_1703EN

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ContinuedPos. Display Function/meaning

5 Stroke time�2�[s]The current stroke time�2 is displayed.Stroke time�2: For example, the time required for drivepiston�2 to move towards the water box.

6 Stroke time�1�[s]The current stroke time�1 is displayed.Stroke time 1: For example, the time required for drivepiston�1 to move towards the cylinder base.

7 Delivery rate�[m3] The current delivery rate is displayed in numbers.8 Stroke counter The number of strokes performed is displayed.

9 Pump operating hoursThe current operating hours of the pump are displayedin numbers.

10 Engine operating hoursThe current operating hours of the engine are dis�played in numbers.


3��55AP21_032_1511EN

The fault codes for the most recent faults are displayed in this menu.

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AP21_032_1511EN 1

2


1 Fault The fault code is displayed.

2 Momentary�contact switchThe last selected HOME menu can be opened bypressing button�(2).

Fault memory


3��56 AP21_033_1703EN

In this menu, you can set setpoint values for the pump output andthe fill level of the delivery cylinders and compare them with theactual values that have been achieved. The delivery rate can becalculated with the operating data specified above.In exceptional cases where there is no information between the en�gine and the controller, you can perform a simulation of the enginespeed.If a fault has occurred in a magnetic switch or resolver, you can set asuitable stroke time.

The colours in the input field have the following meanings:

Colour Function/meaning

Grey Parameter is not active (input is not possible)Green Actual value = setpoint valueYellow Input has not been acknowledged

User settings


3��57AP21_033_1703EN

Function buttons in the user settings menu

1 2 3 4AP21_033_1703EN 1


1 ButtonThe last selected HOME menu can be opened bypressing button�(1).

2 Direction key

Parameters are selected by pressing up or down onthe direction button�(2).The value of the parameter is set by pressing left orright on the direction button�(2).

3 ButtonThe set value for the parameter is acknowledged bypressing button�(3).

4 ButtonThe adjustable values (pump output, fill level of the de�livery cylinders, engine speed and stroke time) can bereset to their factory settings by pressing button (4).


3��58 AP21_033_1703EN

AP21_033_1703EN 2

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1 Setpoint valuesThe specified pump output or the fill level of the deliv�ery cylinders is displayed.

2 Actual value (adjustable)

The pump output or fill level of the delivery cylindersthat has been achieved is displayed.The two parameters are used to calculate the deliveryrate [m3/h].

3In the event of a fault:Actual value (adjustable)

The set stroke time or simulated engine speed is dis�played.

4In the event of a fault:Setpoint values

The specified stroke time or engine speed is dis�played.

→


3��59AP21_033_1703EN

ContinuedPos. Display Function/meaning

5In the event of a fault:Stroke time�[s]

The setpoint and actual values for the stroke time aredisplayed.

6In the event of a fault:Engine speed�[rpm], digital

The simulated engine speed is displayed in numbers.

7Fill level of the delivery cyl�inders�[%]

The setpoint and actual values for the �Fill level of thedelivery cylinders" parameter are displayed.

8 Pump output�[l]The setpoint and actual values for the �Pump output"parameter are displayed.


3��60 AP21_048_1703EN

You can begin a manual lubrication cycle or set the number ofstrokes until the next lubrication in this menu. Parameters such as thenumber of strokes performed since the last lubrication and thenumber of strokes until the next lubrication are displayed.

Function buttons in the lubrication menu

AP21_048_1703EN 1

1 2 3 4 5



2 ButtonA manual lubrication cycle is activated by pressingbutton�(2) in the lubrication menu.

3 Direction keyThe number of strokes between two lubrication cyclesis set by pressing on the left or right of the directionbutton�(3).

4 Button The new setting is saved by pressing button�(4).

5 ButtonThe current settings are reset to the factory settings bypressing button�(5).

Lubrication


3��61AP21_048_1703EN


AP21_048_1703EN 2

1 2 3


1


2 Manually activate a lubrication cycle.

3 Reset to the factory settings.


3��62 AP21_048_1703EN

1

2

3

4

AP21_048_1703EN 3


1Number of strokes, ana�logue

The number of strokes until the next lubrication is dis�played.

2 Number of strokes, digitalThe number of strokes until the next lubrication is dis�played in numbers.

3 Number of strokes, digitalThe number of strokes performed since the last lu�brication is displayed in numbers.

4 Number of strokes, digitalThe number of strokes between two lubrication cyclesis displayed.


3��63AP21_101_1703EN

This menu is used to display the number of active inputs and out�puts. It also allows you to reset the position values for the S transfertube, for example after installing the resolver.

Function buttons in the inputs and outputs menu

AP21_101_1703EN 1

1 2



2 ButtonThe current settings (position values for the S transfertube) are reset to the factory settings by pressing but�ton�(2).

Inputs and outputs


3��64 AP21_101_1703EN


AP21_101_1703EN 2

1 2


1


2The position values for the S transfer tube are reset tothe factory settings.


3��65AP21_101_1703EN

AP21_101_1703EN 3

1 2

3 4


1 IN = inputs, analogueAn overview of all inputs is displayed. The active in�puts are displayed in green.

2Sensor fault = Z1S, Z2S,Z1B, sValve

Sensor faults on the delivery pump are displayed:Z1 rod, Z2 rod, Z1 ground and S transfer tube positionsensor

3 OUT = outputs, analogueAn overview of all outputs is displayed. The active out�puts are displayed in green.

4 IN = inputs, digital The active inputs are also displayed in numbers.


3��66 AP21_102_1703EN

The Ergonic Output Control (EOC) enables you to save the selectedengine speed.You can switch the Ergonic Output Control on and off using the SPCdisplay unit.

HOME menu

AP21_102_1703EN 1

1


1 Symbol: Ergonic Output Control


3.6.3 Ergonic Output Con-trol (EOC)


3��67AP21_102_1703EN

Special features of Ergonic Output Control

If the display is defective or de−energised or a CAN bus fault hasoccurred, the Ergonic Output Control will be switched on automati�cally.

If the display is functioning properly, the Ergonic Output Control willbe switched off after the control system is restarted (switching on theignition). The Ergonic Output Control can be subsequently switchedon/off.

If the Ergonic Output Control is switched on, the pump control sys�tem will behave in the following way:

The engine will be started up at the EOC engine speed if the currentengine speed when the concrete pump is started up is lower thanthe saved EOC speed.The engine will run with no change in speed if the current enginespeed when the concrete pump is started up is greater than or equalto the saved EOC speed.The engine will run with the factory−set EOC speed if no current EOCspeed has been saved.

The engine speed can be set using the control cabinet or the cableremote control. The speed range is limited as follows at the factory:− Min. engine speed = min. EOC speed− Max. engine speed = max. possible pump speedThe current engine speed is saved as a new EOC speed.

The engine is started up at the factory−set idling speed. The enginespeed that was most recently used during pumping operations willbe saved as the EOC speed.

Switch Ergonic OutputControl on/off

Ergonic Output Controlswitched on

Concrete pump start

Concrete pumpswitched on

Concrete pumpswitched off


3��68 AP21_102_1703EN

The factory−set engine speed replaces any saved EOC speed.If the Ergonic Output Control is switched off, the pump control sys�tem will behave in the following way:

The engine will be started up at the factory−set engine speed if thecurrent engine speed when the concrete pump is started up is lowerthan the preset engine speed.The engine will run with no change in speed if the current enginespeed when the concrete pump is started up is greater than the fac�tory−set engine speed.

The engine speed can be set using the control cabinet or the cableremote control. The speed range is limited as follows at the factory:− Min. engine speed = min. preset engine speed− Max. engine speed = max. possible pump speed

The engine is started up at the factory−set idling speed.

Ergonic Output Controlswitched off

Concrete pump start

Concrete pumpswitched on

Concrete pumpswitched off


3��69AP02_988_1501EN

The fuse box is located underneath the �OPS/EGD control cabinet".The operating elements to enable and start DPF regeneration arelocated on the side, as is the momentary−contact switch to overrideengine−related faults.

AP02_988_1501EN 1

1

2

3

4


Meaning/function

1 Fuse box Terminal box for main fuse2 Toggle switch DPF regeneration: On − Off3 Toggle�switch, lo�

cally�latchedPumping operations/DPF regeneration enablement

4 Toggle switch Engine protection override

3.6.4 Fuse box

Right–hand view


3��70 AP02_988_1501EN

Special features of the fuse box

NoteAbbreviations used:EAT = Exhaust After Treatment (after treatment of exhaust gas)DEF = Diesel Exhaust Fluid (urea solution used in exhaust gas treat�ment, e.g. �AdBlue")DPF = Diesel Particle FilterDOC = Diesel Oxidation CatalystSCR = Selective Catalytic Reduction

To operate a locally latched toggle switch, you must first pull it outand then push it towards the symbol.

Engine protection override can only be used to override engine−re�lated faults (e.g. coolant level too low, quantity of water in fuel toohigh, engine overheating, etc.). It is not possible to override exhaustafter treatment (EAT) faults in this way.

NoteIf the engine overheats, it switches off automatically (see �En�gine�status" symbol in the EGD of the OPS/EGD control cabinet).In emergency operation, the �Engine protection override" momen�tary−contact switch must be permanently held down when switchingon and continuing to run the engine.

Locally latched toggleswitches

Engine protection over�ride toggle switch


3��71AP02_988_1501EN

NoteWhen the �DPF regeneration" warning symbol lights up in yellow inthe EDG of the �OPS/EDG control cabinet", you need to start the re�generation procedure/stationary regeneration �manually" at the fusebox.The regeneration procedure can only be started �manually" if the fol�lowing conditions are met:� You have positioned the machine in the open, on terrain with a

sufficient distance from other machines, combustible materialsand flammable liquids.

� The engine speed must be lowered to idling speed.� Output must be reduced to 0%.� The engine must be in a no−load condition.� The engine must be warm (coolant temperature higher than 70 °C

and exhaust gas temperature downstream of the DOC lower than250 °C).

� The SCR system to reduce nitrogen oxide (NOx) must be active.� The �Fill level of the DEF container" warning symbol must display a

value higher than 15%.� The DEF container must not be frozen.

Once all the conditions listed above have been met, you can startthe DPF regeneration procedure at the DPF fuse box.The DPF regeneration procedure takes approx. 40 minutes.


3��72 AP02_988_1501EN

Start the DPF regeneration procedure at the fuse box as follows:− Switching the toggle switch from �Pumping operations" to �Enable

DPF regeneration" interrupts pumping operations and enables theDPF regeneration procedure. The EMERGENCY STOP status istriggered at the same time.

− Pressing the toggle switch to �DPF regeneration on" starts the DPFregeneration procedure.

Once the DPF regeneration procedure is complete, you can onlystart up the pump again as described below:− Switch the toggle switch on the fuse box from �Enable DPF regen�

eration" to �Pumping operations".− Press the �Deactivate EMERGENCY STOP" toggle switch on the

remote control.− Press the �Acknowledge agitator safety cutout" toggle switch in

the operating panel.− Press the �Pump On" toggle switch on the remote control.

Manually starting theDPF regeneration pro�cedure

Starting up the pumpafter performing theDPF regeneration pro�cedure


3��73AP02_988_1501EN

Stop the DPF regeneration procedure at the fuse box as follows:− Pressing the toggle switch �DPF regeneration�On�−�Off" again in�

terrupts the DPF regeneration procedure or stops the procedure.− Switching the �Pumping operations/Enable DPF regeneration"

toggle switch from switch position �Enable DPF regeneration" to�Pumping operations" interrupts the DPF regeneration procedureor stops the procedure.

It is not advisable to interrupt the DPF regeneration procedure. Thenumber of DPF regeneration procedures that have been interruptedis logged in the control unit.

NoteIf you interrupt a DPF regeneration procedure due to a yellow �DPFregeneration" warning symbol, the exhaust after treatment systemwill activate further escalation levels (depending on the length of thepumping operation).The result is that power reduction level�2 is activated in the last es�calation level if there is a red �DPF filter maintenance required" warn�ing symbol Pumping operations and DPF regeneration are disabled.A service employee of the engine manufacturer must replace theDPF filter.The engine can only be enabled using service software from the en�gine manufacturer (SERDIA service tool).

Manually stopping theDPF regeneration pro�cedure


3��74 AP02_905_1304EN

The most important control functions for the pump are gatheredtogether on the cable remote control, so that you can control theoperation of the pump from here.

AP02_905_1304EN 1

1 2

34

No. 0 Operating/control element Meaning/function Comments

1 Momentary�contact switch EMERGENCY STOP

2 Toggle switch Increase�speed�− Reduce�speed

3 Toggle switch Deactivate EMERGENCY STOP

4 Toggle switch Pump�On�− 0�− Reverse�pumping

NoteYou need only press one of the EMERGENCY STOP buttons totrigger an EMERGENCY STOP of the machine.

To release the EMERGENCY STOP condition again, you must unlockthe EMERGENCY STOP button that has been pressed by turning it.

You must press the �Deactivate EMERGENCY STOP" toggle switchto make the pump start up once more.

3.6.5 Cable remote control


3��75AP02_905_1304EN

Special features of the cable remote control

The red �EMERGENCY STOP activated" indicator lamp on thecontrol cabinet lights up and the green �Pump running" indicatorlamp flashes if you have pressed the EMERGENCY STOP button.You can only restart the pump as described below:− Unlock the EMERGENCY STOP button by turning it.− Operate the �Deactivate EMERGENCY STOP" toggle switch.

� The red �EMERGENCY STOP activated" indicator lamp onthe control cabinet goes out.

− Switch the pump on.

Starting up the pumpafter EMERGENCYSTOP


3��76 AP02_846_1203EN

EMERGENCY STOP buttons are fitted to the following machine com�ponents:− the cable remote control− the right�hand side of the machine, near the operating elements.

CautionFamiliarize yourself with the positions of the EMERGENCY STOP but�tons on your machine.

30505901

EMERGENCY STOP button

NoteYou need only press one of the EMERGENCY STOP buttons totrigger an EMERGENCY STOP of the machine.

To release the EMERGENCY STOP condition again, you must unlockthe EMERGENCY STOP button that has been pressed by turning it.

You must press the �Deactivate EMERGENCY STOP" toggle switchto make the pump operational once more.

3.6.6 EMERGENCY STOPbutton


3��77AP02_846_1203EN

The following actions are triggered when you press one of theEMERGENCY STOP buttons:− the EMERGENCY STOP symbol lights up red on the EPS/EGD

control cabinet,− variable main pumps swing back, the delivery pistons come to a

halt,− the change�over valve is disconnected.

NoteIf the machine has an electrical agitator safety cutout, the accumula�tor dump valve is opened and the accumulator emptied when theEMERGENCY STOP button is pressed. The agitator will stop.

To start up the agitator again, you must actuate the �Acknowledgeagitator / agitator safety cutout" toggle switch on the control cabinet.


3��78 AP02_855_1609EN

The agitator safety cutout consists of a transponder and an evalu�ation device with reading head. As soon as you open the grille, theradio link between the transponder and the reading head is broken.This causes the agitator to halt and the pressure to be dumped fromthe accumulator (if fitted) or the change−over valve to be de−ener�gized, i.e.� the transfer tube will no longer be able to switch over. Inaddition, the delivery pistons return to the end position and the con�crete pump halts. To restart the concrete pump, you must first switchit off and then back on again. In order that the agitator starts turningagain and the accumulator refills, you must acknowledge the agitatorsafety cutout on the control cabinet.

1

4

AP02_855_1609EN 1

3

2

Pos.0 Designation

1 Transponder (on the grille)2 Acknowledge agitator or agitator safety cutout

on the control cabinet3 Green and red LEDs4 Reading head (on the hopper − example illustration)

3.6.7 Agitator safety cutout(RSA)


3��79AP02_855_1609EN

NoteIf the evaluation device becomes defective, the agitator safety cutoutis triggered and the agitator, transfer tube and concrete pump arestopped.

Therefore, always check that the agitator safety cutout is workingproperly before using the pump.

The LEDs on the evaluation device indicate the following information:� The green LED flashes for 8�seconds during the initialization pro�

cess.� The green LED lights up during normal operation when the grille is

closed.� The green LED flashes when the grille is open.� The red LED lights up when there is a fault with the evaluation de�

vice.


3��80 AP02_853_1202EN

The distributor casing for the magnetic switches is located beneaththe control cabinet.

AP02_853_1202EN 1

1 3

2 45

No. 0 Control element Meaning/FunctionBelongswith no.:

1 Yellow LED Magnetic switch (rod side), drive cylinder II2 Yellow LED Magnetic switch (rod side), drive cylinder I3 Female connector Not assigned4 Yellow LED Magnetic switch (piston side), drive cylinder I5 Green LED In service lamp

3.6.8 Magnetic switchesdistributor casing


3��81AP02_853_1202EN

Special features of the distributor casing

There are three magnetic switches in the core pump drive cylinders,one on the rod side in each of the two cylinders and one on the pis�ton side in the right−hand cylinder. These switches trigger the switch�over procedure when the hydraulic pistons approach the magneticswitches. The LEDs for the magnetic switches that have just beentriggered light up on the distributor casing at the same time.

LED for magnetic switch Magnetic switch status

lights up briefly on switchover Magnetic switch is OK

does not light up despitetriggering

Magnetic switch, connector orlead are defective, replace im�mediately as switchover is no

lights up continuouslymediately, as switchover is nolonger possible

In service lamp Distributor casing status

lights up continuously The distributor casing is readyfor operation.

does not light up The Putzmeister operating sys�tem is not supplied with a volt�age.

NoteAdditional LEDs are located on the magnetic switch connector (seepage 3��83). These LEDs indicate whether it is the magnetic switchor the connector and lead that is defective.

LEDs


3��82 AP02_853_1202EN

Electronic stroke correction on this machine takes place as required.As soon as the piston side magnetic switch in drive cylinder�1 is trig�gered, it always resets the set time to zero. If this magnetic switch isno longer triggered, the set time (e.g.�1�min) counts down. If the timehas elapsed, the rod side magnetic switch in drive cylinder�2 iscleared. This means that switchover only occurs through the pistonside magnetic switch in drive cylinder�1. Once this has been trig�gered again (stroke correction has taken place), the cleared rod sidemagnetic switch is reconnected and the time is reset to zero.

NoteThe machine could make loud noises during stroke correction sincethe hydraulic fluid is pressed through the stroke correction line athigh pressure.

Stroke correction


3��83BP02_428_9707EN

The connector for the magnetic switch has one yellow and one greenlight−emitting diode. These LEDs indicate the status of the connectorand the magnetic switch.

20500406

2

3

1

No. 0 Designation

1 Green and yellow LEDs2 Connector3 Magnetic switch

NoteThe yellow LED indicates the status of the magnetic switch, thegreen LED indicates the status of the connector and the lead.

3.6.9 Magnetic switchconnector


3��84 BP02_428_9707EN

Yellow LED Magnetic switch status

lights up briefly on switchover Magnetic switch is in order

does not light up on switchover Magnetic switch is defective,replace at earliest opportunity

lights up continuously Magnetic switch is defective,remove connector from themagnetic switch (otherwiseswitchover is not possible) andreplace at earliest opportunity

Green LED Connector and lead status

lights up A voltage is being applied to theconnector, i.e. connector andlead are in order

does not light up No voltage is being applied tothe connector, i.e. connector orlead are defective

Significance ofthe LEDs


3��85AP02_910_1304EN

The hydraulic control devices and operating elements on this ma�chine are described on the following pages. The overview at the startof this chapter will show you where the various control devices arelocated on the machine. The symbols used on the hydraulic controldevices are described in one of the preceding sections.

The hydraulic control devices may include the following components,depending on the equipment on your machine.− Output controller− �Engine stop" handle− Pressure gauge− Engine manual throttle lever− Water pump lever− Pump control system− Emergency operation of the agitator and water pumps− Condition of the pressure filter

NoteFurther control devices and components are described in the sec�tions entitled �Electrical control devices" (from page�3��20) and�Other components" (from page�3��91).

3.7 Hydraulic controldevices


3��86 AP21_010_1505EN

The output controller�(1) is used to open/close an adjustment valve,so that the output is increased or reduced. If the output controller�(1)shows �min", the delivery cylinders remain stationary − the concretepump is switched off.

AP21_010_1505EN 1

1

" Operate the output controller�(1) to adjust the output.

No. 0 Designation

1 Output controller

3.7.1 Output controller


3��87AP02_245_1402EN

The water pump lever is used to switch the water pump on or off.

AP02_245_1402EN 1

1

2

No.0 Designation

1 Water pump off2 Water pump on

3.7.2 Water pump lever


3��88 AP21_076_1609EN

The hydraulic control valves are built into the pump control system.They are only for emergency manual operation of the machine whenthe control system fails.

AP21_076_1609EN 1

Pos.0 Designation

1 Emergency operation � transfer tube2 Drive cylinder emergency operation

3.7.3 Pump control system


3��89AP21_054_1609EN

If the control panel has failed, you can use different directions ofrotation to manually operate the agitator from the hydraulic controlblock illustrated below.

AP21_054_1609EN 1

1

1

Pos. 0 Designation

1 Agitator emergency operation

3.7.4 Agitator emergencyoperation


3��90 AP02_063_0308EN

The hydraulic pressure of the hydraulic pump is shown on thepressure gauge.

AP02_063_0308EN 1

The condition of the suction filter can be seen on the vacuum meter,that of the pressure filter can be seen directly on the filter housing.

AP02_063_0308EN 2

Vacuum meter

AP02_063_0308EN 3

Filter housing with indicator

3.7.5 Pressure gauge

3.7.6 Filter condition

Suction filter

Pressure filter


3��91AP02_059_9801EN

The other components of this machine are described on the follow�ing pages. The summary at the start of this chapter will show youwhere the various components are located on the machine. Thesymbols used on the other components are described in one of thepreceding sections.

The following components may be described here, depending onthe equipment on your machine.− manual throttle lever for the engine− flushing water pump− high−pressure water pump− compressor− vibrator− hydraulic fluid radiator

NoteFurther control devices and components are described in the �Hy�draulic control devices" (from page 3��85) and �Electrical controldevices" (from page 3��20) sections.

3.8 Other components


3��92 AP02_787_1008EN

Depending on the machine specification, it may be equipped witheither a Hypro WP 50 or a CRK 4−160.

The flushing water pump Hypro WP 50 generates a water pressure of20�bar at a water delivery rate of 50�litres per minute maximum.

11201701

1 3

4

5

2

6

No. 0 Designation

1 High−pressure water hose2 Water pressure gauge3 Pressure limiting valve4 Claw coupling for high−pressure water hose5 Flushing water pump6 Claw coupling for the water supply

3.8.1 Flushing water pump

Flushing water pumpHypro WP 50


3��93AP02_787_1008EN

The flushing water pump CRK 4−160 generates a maximum waterpressure of 25�bar and a maximum water delivery rate of 160�litresper minute.

AP02_787_1008EN 1

1

2

3

5

4

No. 0 Designation

1 Water pressure gauge2 Connector for water hose3 Flushing water pump4 Hydraulic ports5 Hydraulic motor

Flushing water pumpCRK 4–160


3��94 AP02_014_9612EN

The vibrator is bolted to the grille. It causes the grille to vibrate andthus prevents bridges forming on the grille, particularly in the case ofvery stiff concrete. The vibrator is electrically driven; the connectingplug must be plugged into the appropriate socket on the controlcabinet for this to work.

31201000

1

2

3

4

No 0 Designation

1 Grille2 Vibrator3 Supply cable4 Plug

The vibrator is switched on and off from the control cabinet, oroptionally through the remote control.

3.8.2 Vibrator


3��95AP02_987_1702EN

This section provides a description of the exhaust after treatmentsystem.The engine and its exhaust after treatment system are coordinatedwith one another and form a complete engine system. The completeengine system meets the permitted exhaust gas emission levels andis certified accordingly by the relevant authorities.

DangerRisk of burning when touching components that conduct exhaustgases.In particular during the diesel particle filter (DPF) regeneration pro�cedure, extremely high exhaust gas and surface temperatures ariseat the exhaust after treatment system.Maintain a sufficient distance from the exhaust after treatment sys�tem. Use your personal protective equipment.

CautionIt is not permissible to operate the engine using a different exhaustafter treatment system.It is not permissible to carry out unauthorized changes to the exhaustafter treatment system. The engine manufacturer is not liable for anydamage caused as a result.Only operate the engine if the exhaust after treatment system isworking correctly; otherwise the permitted exhaust gas emission le�vels may not be met.Observe the applicable national exhaust gas emission regulations toensure compliance with exhaust gas emission levels.

CautionFailure to comply with the requirements and recommendations forfunctional fluids of the engine manufacturer may result in damage tothe complete engine system.Observe the requirements and recommendations for operating ma�terials (lubricating fluid, permitted fuels, coolant and diesel exhaustfluid) in the engine manufacturer’s documentation.

3.8.3 Exhaust after treat-ment system


3��96 AP02_987_1702EN

NoteRefer to the engine manufacturer’s documentation for details abouthow the exhaust after treatment system works.Abbreviations used:EAT = Exhaust After Treatment (after treatment of exhaust gas)DEF = Diesel Exhaust Fluid (urea solution used in exhaust gas treat�ment, e.g. �AdBlue")DPF = Diesel Particle FilterDOC = Diesel Oxidation CatalystSCR = Selective Catalytic ReductionNOx = Nitrogen Oxide


3��97AP02_987_1702EN

Selective Catalytic Reduction (SCR)

AP02_987_1702EN 1

1

2

456

7

7

10

11

8

9

3 3

Example illustration: SCR system

Pos.0 Component

1 Engine control unit2 Solenoid−operated valve3 Line heated with coolant (to preheat the DEF container)4 DEF container5 DEF delivery pump6 DEF line7 Line cooled with coolant (to cool the metering unit)8 SCR catalytic converter9 Metering unit

10 Exhaust gas temperature sensor11 NOx sensor


3��98 AP02_987_1702EN

The SCR system continuously reduces the NOx emissions producedby the engine as described below:The DEF delivery pump supplies the diesel exhaust fluid (DEF) thatis injected into the exhaust system by the metering unit upstream ofthe SCR catalytic converter.The DEF injected into the exhaust system reacts with the NOxemissions present in the exhaust gas in the catalytic converter of theSCR system. This reduces the NOx emissions to nitrogen (N2) andwater (H2O).The engine control unit controls the DEF injection volume.

CautionLeaking DEF lines may cause damage to electrical and electroniccomponents in the engine compartment.Leaking diesel exhaust fluid (DEF) can cause corrosion damage andoperating faults if it comes into contact with cabling, control unitsand similar electronic components (e.g. short circuiting, malfunctionsand the destruction of electronic components).Check the DEF lines and line connections for leak tightness. Sealany leakage points.Electronic components (e.g. sensors) that can come into contactwith DEF must be connected using lines that are sealed all the wayalong.


3��99AP02_987_1702EN

Diesel Oxidisation Catalyst/Diesel Particle Filter (DOC/DPF module)

AP02_987_1702EN 2

12

34

Example illustration: Diesel particle filter (DPF)

Pos.0 Component

1 DOC � diesel oxidisation catalyst2 Exhaust gas temperature sensor3 Pressure differential sensor4 DPF � diesel particle filter


3��100 AP02_987_1702EN

The diesel oxidisation catalyst (DOC) oxidises the carbon monoxide(CO) and unburned hydrocarbons (HC) present in the exhaust gas.Within a temperature range of 200°C to 450°C, nitrogen monoxide(NO) is converted into (NO2) through oxidation.

The diesel particle filter (DPF) with passive regeneration capabilitiesseparates the soot created during the diesel fuel combustion pro�cess. The DPF must be regenerated as soon as it becomes increas�ingly loaded with soot.The passive diesel particle filter is regenerated by burning the sootparticles using the nitrogen oxide (NOx) contained in the exhaustgas.The continuous DPF regeneration procedure lasts approx. 40 min�utes and takes place at exhaust gas temperatures of approx. 580°Con the DOC/DPF module.The engine control unit monitors the loading of the diesel particlefilter.


3��101AP02_987_1702EN

DPF regeneration strategy

NoteRefer to the engine manufacturer’s documentation for details aboutthe regeneration strategy.

Danger of fireRisk of fire due to an inadequate clearance from a stationary con�crete pump during the regeneration procedure.During the regeneration procedure in particular, very high exhaustgas and surface temperatures occur near a stationary concretepump (approx. 600°C).Activate the regeneration procedure out in the open air only.Select a set−up site that has sufficient clearance from other ma�chines, combustible materials and flammable liquids.Use your personal protective equipment.

DangerRisk of burning when touching components that conduct exhaustgases.During the stationary regeneration in particular, very high exhaustgas and surface temperatures occur at the exhaust after treatmentsystem (approx. 600°C).You are not permitted to use the machine during stationary regener�ation.Maintain a sufficient distance from the exhaust after treatment sys�tem. Use your personal protective equipment.


3��102 AP02_987_1702EN

Regeneration strat-egy/colour code

Description/DPF soot load ErgonicGraphicDisplay

Buzzer Power reduction

Normal operation

Dark greenRegeneration not required.DPF soot load < 62%

Off Off None

Passive regener-ation 1 =Heat mode 1

RequiredPassive regeneration takesplace continuously during en�

Green

place continuously during engine operation.Actions inside the engine areenabled.DPF soot load > 62%

Off Off None

Passive regener-ation 2 =Heat mode 2

RequiredPassive regeneration takesplace continuously during en�

Green

place continuously during engine operation.Actions inside the engine areenabled.DPF soot load > 78%

Off Off None

Active regener-ation =Standstill

Regeneration required.Operation can continue but re�generation is urgently required.

Yellow

generation is urgently required.Active regeneration must be in�itiated manually by the machineoperator.DPF soot load > 100%

On Off None


3��103AP02_987_1702EN

Regeneration strat-egy/colour code

Description/DPF soot load ErgonicGraphicDisplay

Buzzer Power reduction

Active regener-ationWarning level

Regeneration required.Operation can continue but re�generation is urgently required.

Orange

generation is urgently required.Active regeneration must be in�itiated manually by the machineoperator.DPF soot load > 109%

On On 25%

Active regener-ationSwitch–off step

Regeneration using ServiceTool required.R ti i i iti t d b

50% of max. torqued

Red

Regeneration is initiated byDEUTZ After Sales department.

DPF soot load > 125%

On Onand

speed limit 60% ofthe nominal speed

Filter change Filter change required.50% f t

Dark red

Filter change required.Filter is changed by DEUTZAfter Sales department.Regeneration not permissible.DPF soot load > 156%

On On

50% of max. torqueand

speed limit 60% ofthe nominal speed



Starting�up

4��IAP13_015_0303EN

4 Starting up

In this chapter you will learn the steps necessary when starting upyour machine for the first time, and how to prepare your machine foruse if left idle for a prolonged period.

Information is available on how to check your machine and how tocarry out a test run with visual and function checks.

NoteThe operating personnel must be instructed in the use of themachine the first time it is started up.

Starting�up

4��II AP13_015_0303EN

Starting�up

4��1AP13_022_0303EN

You must check the condition of the machine and carry out a test runwith function checks each time before you start to use it. If you noticea defect, you must have this rectified immediately, if necessary byqualified personnel.

NoteEvery time you use the machine, you accept full responsibility for thesafety of anyone located in the machine’s danger zone. You aretherefore under an obligation to ensure that the machine is com�pletely safe in operation.

The fundamental prerequisite for problem−free use is a fully func�tional hydraulic system.

" Check that all hydraulic lines, threaded unions and cylindersare tight.

Maintenance card: Hoses

CautionOperation is not possible if the hydraulic cylinders are leaking,please consult Putzmeister After Sales Department.

4.1 Visual checks

4.1.1 Hydraulic system

Starting�up

4��2 AP13_022_0303EN

Making ready for operation also includes topping up the functionalfluids.

10000702

MAX

MIN

MAX

MIN

Water, fluid and fuel levels

DangerOils, fuel and other functional fluids may be injurious to health oncontact with the skin, etc.You must, therefore, always wear personal protective clothing andequipment when you are handling toxic, caustic or other functionalfluids that are injurious to health and always take note of the manu�facturer’s information.

NoteThe machine must be level when you check the functional fluids. Thewater box must be full during operation, even if there is a risk offreezing.

" Check all water, fluid and fuel levels and top these up asnecessary.

4.1.2 Functional fluids

Starting�up

4��3AP13_022_0303EN

Water of condensation can form in the hydraulic fluid reservoir andsettle at the deepest point if the machine is shut down for some time.

AP13_022_0303EN 1

" Place a suitable container under the drain cock to catch theescaping condensate water.

" Open the drain cock. Close the cock again as soon as fluidruns out.

" Check that all lubrication lines are tight and free from fracture.

" Check that all lubrication points have been lubricated.

" Check the hydraulic fluid radiator and, if necessary, carefullyclean the radiator panel.

4.1.3 Condensate water

4.1.4 Lubrication points

4.1.5 Hydraulic fluidradiator

Starting�up

4��4 AP13_022_0303EN

The water box is fitted between the drive cylinders and deliverycylinders. To be able to better check the water level and the condi�tion of the water, you have to open the water box, i.e. remove theperforated plate.

Danger of crushingYou could suffer severe injuries from crushing or the shearing actionof components.

Never reach into the open water box to check it.

" Open the water box.

" Check the water level.� The piston rods must be completely covered.

" Check the water condition.� The drive cylinders are leaking if there is a clearly visibleescape of fluid, particularly at the piston rods.� At least one of the delivery pistons is worn if the amount ofsludge in the water box is unusually high.

" Check the securing wires on the bolts on the spacer flange.� Check the tightening torques on the bolts if the securingwires are damaged.

Maintenance card: Delivery piston replacement

" Close the water box again.

NoteSmall quantities of fluid in the water box originate from the dry run�ning cut−out for the delivery pistons. The drive cylinders are onlyleaking if there is a clearly visible escape of fluid.

4.1.6 Water box

Starting�up

4��5AP13_022_0303EN

You should always check the parts which come into contact withconcrete before using the machine:

" Disconnect the delivery line bend at the pressure connection.

" Illuminate the transfer tube from the pressure connection usinga pocket torch and check the inner wall of the pipe and itsthrust ring for wear.

" Reconnect the delivery line bend to the pressure connection.

" Look into the hopper and check on the condition of the spec�tacle wear plate and the wear ring. The parts must be replacedif there is clearly detectable wear (e.g. deep grooves).

10701400

Check spectacle wear plate

" Check that all safety equipment is fitted and fully functional.

CautionThe agitator grille must be closed and secured.

4.1.7 Parts in contactwith concrete

Starting�up

4��6 AP13_103_1501EN

Depending on the machine’s equipment, the following sequence ofactions must be carried out for the test run:− Open the ventilation flap (as soon as the machine is warm)− Open the side flaps (as soon as the machine is warm)− Switching on the machine

You must now check several functions with the machine running.

CautionThe ventilation flap must be open before you switch on the machine.

All operating elements on the control cabinet, in particular the mainswitch and the EMERGENCY STOP button, must be quickly access�ible at all times during operation.

The side flap in front of the control cabinet must not be closed oncethe engine has been switched on if this obscures the operating el�ements.

CautionDamage to the engine caused by potential malfunctions in the fueland exhaust after treatment system.Bleeding the fuel system is also urgently required. Start the five−min�ute test run while idling up to an operating temperature of approx. 90°C.Check the leak tightness of the engine, the lubricating fluid pressureand the lubricating fluid level.Check the exhaust after treatment system for leak tightness.The SCR system requires a warming up and thawing phase of ap�prox. 30 minutes at ambient temperatures of below 0 °C. The heatedSCR components (e.g. DEF containers, DEF lines and DEF deliverypump) are thawed.Observe the requirements and recommendations in the enginemanufacturer’s documentation.

4.2 Test run

Starting�up

4��7AP13_073_1111EN

Before switching on the machine, you must set up the machine cor�rectly, have the control cabinet connected to the electrical powersupply and must set up the cable remote control for use.

You can find information on this in the chapter entitled �Transport,setting up and connection".

The engine can only be switched on when it is under no load, i.e.there must be no consumers switched on.

" Switch the agitator off.

" Turn the �Increase − Reduce output" potentiometer on thecable remote control to �min".

AP13_073_1111EN 1

1

2

No. 0 Designation

1 Ergonic Graphic Display (EGD):Setting and displaying operating states

2 Ignition�starter switch: Diesel engine On−Off

4.2.1 Switching onthe machine

Switching onthe engine

Starting�up

4��8 AP13_073_1111EN

NoteTo operate the machine locally, the �Local control" connector mustremain plugged into the �Local control − remote control" socket onthe control cabinet.

1

AP13_073_1111EN 2

No. 0 Designation

1 �Local control" connector

" Plug in the �Local control" connector.

" Switch on the diesel engine using the ignition�starter switch.� The Ergonic Graphic Display lights up.

" Actuate the �Deactivate EMERGENCY STOP" toggle switchon�the control cabinet.

" Switch on the pump using the �Forward pumping − 0 − reversepumping" toggle switch on the control cabinet.

" Set the required delivery rate on the output controller, besidethe control cabinet.

" You can use the EGD operating elements to navigate in themenu structure and to make settings.

Starting�up

4��9AP13_026_0510EN

Before using the machine on site, systematically check the functionsof the components with the machine running.

The fundamental prerequisite for problem−free use is a fullyfunctional pump.

Check for an unimpeded switchover function of the delivery pistonsand the transfer tube at various engine speeds and positions of theoutput controller.

AP13_026_0510EN 1

Checking the magnetic switches

Check that the drive cylinders switch over automatically once thehydraulic pistons are close to the magnetic switches. The greenin−service lamp on the distributor casing must remain lit duringthis�process. The yellow LEDs will light up briefly as soon as thehydraulic piston approaches its magnetic switch. If one of the LEDsdoes not light up, the associated magnetic switch is defective.

4.3 Function checks

4.3.1 Pump

Switch over

Magnetic switches

Starting�up

4��10 AP13_026_0510EN

Press and hold the change−over button at low delivery piston speed.The delivery pistons move to their end positions. Stroke correction isautomatic and is complete when both delivery pistons come to a halt(may be seen in the water box).

Measure the machine stroke time under no load, i.e. withoutconcrete.

" Set the engine to maximum speed.

" Set the maximum pumping rate.

" Start the measurement at the first switch over of the transfertube.� The first single stroke is complete with the next transfertube switch over.

" Measure the stroke time over a period of ten single strokes.

The value measured, divided by ten, must match the data in the testreading.

NoteDue to differences in reaction times when using the stopwatch, thevalue determined may vary from the value stated by approximately 5%.You may have to take the measurement several times and calculatethe mean of the values measured.

Stroke length

Stroke time

Starting�up

4��11AP13_027_0904EN

It is only possible to intervene rapidly in the event of danger if allEMERGENCY STOP buttons on the machine and on the remotecontrol are functioning correctly.

CautionThe machine is no longer safe to operate if an EMERGENCY STOPbutton is defective, as you will no longer be able to switch off themachine quickly enough if danger threatens. You must thereforecheck the functioning of the EMERGENCY STOP buttons each timeyou start work.

10500200

Press: lock EMERGENCY STOPTurn: unlock EMERGENCY STOP

" Switch the pump on.

" Operate a control function (e.g. �Reverse pumping On").

" Press one of the EMERGENCY STOP buttons.� The pump must stop immediately.

" Check all EMERGENCY STOP buttons on the machine andon�the remote control in the same way.

4.3.2 EMERGENCY STOPbuttons

EMERGENCY STOPbutton

Starting�up

4��12 AP13_075_1610EN

This machine is equipped with an agitator safety cutout. As soon asyou open the grille, the signal between the transponder and readinghead is broken. This causes the agitator to halt and the pressure tobe dumped from the accumulator, i.e. the transfer tube will no longerbe able to switch over. In addition, the delivery pistons return to theend position and the concrete pump halts.

DangerRisk of injury when the agitator is operating and the transfer tube isswitching.

A defective agitator safety cutout can cause you to believe that themachine is safe, even though this is not really the case. This canlead to the agitator continuing to run or the transfer tube switchingover when the grille is open.

You must therefore check the function of the agitator safety cutoutbefore you start each pumping job.

Before acknowledging the agitator safety cutout, check that no�oneis in any danger.

You must stop work if you open the grille, but� the agitator continues to run, or� the transfer tube continues to switch over, or� the concrete pump does not run to its end position.

4.3.3 Function check of theagitator safety cutout(RSA)

Starting�up

4��13AP13_075_1610EN

AP13_075_1610EN 1

1 2

4

3

Pos.0 Designation

1 Transponder (on the grille)2 Green and red LEDs3 Acknowledge agitator or agitator safety cutout

on the control cabinet4 Reading head (on the hopper − example illustration)

" Open the grille with the concrete pump running.� The transponder signal is broken.� The agitator must come to a halt immediately.� The transfer tube must no longer switch over.� The concrete pump must run to the end position and halt.

NoteTo restart, you must first acknowledge the agitator or agitator safetycutout toggle switch on the control cabinet.

Starting�up

4��14 AP13_076_1610EN

The agitator is secured against unexpected restarts. When the ma�chine is started up after the agitator safety cutout has been actuated,the agitator safety cutout must be acknowledged before the concretepump can be switched back on.

The agitator safety cutout is triggered in the following situations:− When the grille is opened− When the power take�off is switched off− When the ignition is switched off




Before acknowledging the agitator safety cutout, check that no�oneis in any danger.


4.3.4 Acknowledging theagitator safety cutout

Starting�up

4��15AP13_076_1610EN

AP13_076_1610EN 1

1

Pos.0 Designation

1 Acknowledge agitator or agitator safety cutout on the control cabinet

" Actuate the �Acknowledge agitator or agitator safety cutout"toggle switch on the control cabinet.

Starting�up

4��16 AP13_029_0308EN

Dirty filters reduce the fluid flow considerably so that damage mayoccur in the hydraulic system.

" Bring the hydraulic fluid up to operating temperature (�50�_C).

" Set the maximum pumping rate.

NoteThe indicators on the filters can only be checked under load oncethe hydraulic fluid has warmed up.

Please read the �Filter change" maintenance card.

10300200

Vacuum meter

NoteYou must replace the filter element if the pointer on the vacuummeter is in the red zone at more than 50�_C fluid temperature andat�the shortest stroke time.

4.3.5 Filter condition

Suction filter

Starting�up

4��17AP13_029_0308EN

AP13_029_0308EN 1

Pressing down the red button

" Press down the red button on the filter if it is sticking up.

NoteYou must replace the filter element if the red button pops out againafter a short time.The filter is OK if the red button remains depressed.

Environmental protectionComply with the waste disposal regulations in force for your areawhen changing the fluid filter.

Pressure filter

Starting�up

4��18 AP13_074_1111EN

The agitator hopper grille must always be closed when the pump isin operation.

20203003

1a

1b

1

No. 0 Designation

1

Agitator On − agitation direction away from the deliverycylinder�(1a)Agitator OffAgitator On − agitation direction towards the delivery cylinder�(1b)

" Actuate the toggle switch on the control cabinet and check thetwo directions of rotation, one after the other.

4.3.6 Agitator

Starting�up

4��19AP13_033_1008EN

Depending on the machine specification, it may be equipped witheither a Hypro WP 50 or a CRK 4−160.To prevent damage, never run the flushing water pump without water.You may, however, perform a short function test lasting a few secondswithout the water being connected.

NoteThe agitator, gate valve and flushing water pump can not be operatedat the same time since they are all driven off the same hydrauliccircuit.

1 2

AP13_033_1008EN 1

No. 0 Designation

1 Flushing water pump On2 Flushing water pump Off

" Check the flushing water pump inlet screen and, if necessary,clean it before operation.

" Switch the agitator off and switch the gate valve to neutral.

" Check that the flushing water pump is functioning correctly.

4.3.7 Flushing water pump

Starting�up

4��20 AP13_034_0303EN

The vibrator is electrically driven so an electrical connection mustfirst be made between it and the control cabinet.

31201000

1

2

3

4

" Check that the vibrator is functioning correctly.

NoteThe vibrator will only function when the switch for the pump is on atthe control cabinet and at the remote control.

4.3.8 Vibrator

Starting�up

4��21AP13_122_1709EN

When you shut down the machine, you must perform the followingtasks:

Switch off the pump at the control cabinet.

" Set the output controller to �min".

" Switch off all power consumers.

The following section describes the procedure for switching off themotor.

NoteIf you switch off the ignition, the control unit for the electronic enginegovernor (EMR4) is still supplied with power for approx. two�minutes.During this run−down time, required data is saved in the control unit,and the DEF lines are emptied (risk of freezing).

CautionDo not switch off the motor when running at full load.

Only use the EMERGENCY STOP button in the event of danger.

4.3.9 Switching off the ma-chine

Switches off the pump

Shutting down themotor

Starting�up

4��22 AP13_122_1709EN

CautionYou must only disconnect or switch off the battery once the controlunit has completed its run�down time (approx. two�minutes). Inter�rupting this run�down time will cause a fault in the control unit.This fault is shown continuously in the display, which means that yourun the risk of overlooking other faults.When you switch off the engine, you must follow the instructionsbelow:� Only switch off the engine using the ignition−starter switch.� Do not unplug the control unit connector when the power supply is

switched on (ignition�on).� If maintenance work is to be carried out on the machine (e.g.�elec�

trical welding work), you must always disconnect all plug�in con�nections from the control unit.

Putzmeister will not accept warranty claims for engine damage andoperating errors that result from a failure to switch off the engine ac�cording to the instructions.

Starting�up

4��23AP13_122_1709EN

AP13_122_1709EN 11

Example illustration

Pos. 0 Designation

1 Ignition�starter switch: Diesel engine On−Off

" Switch off the ignition�(1).� The control unit saves required data during the run−downtime (approximately two�minutes).

Starting�up

4��24 AP13_122_1709EN

If you interrupt the run−down time of the control unit, the followingfaults may occur:

NoteBecause the faults listed here are not control unit malfunctions, butoperating errors, the work involved in rectifying them is not coveredby the warranty, as stated in the general terms and conditions ofDEUTZ.

Fault Cause Remedy

Main relay switchesto passive state

Engine switched off,as the battery is dis�connected/switchedoff

DEUTZ servicetechnician rectifiesfault

EEPROM memoryfault

The engine wasswitched off usingthe ignition−starterswitch, but the bat�tery was discon�nected/switched offbefore the run−downtime expired.

DEUTZ servicetechnician rectifiesfault

Possible faults

Transport,�setting�up�and�connection

5��IAP06_001_1007EN

5 Transport, setting up and connection

This chapter contains information relating to transporting the ma�chine. Tasks required for setting up and connecting the machine arealso described.


5��II AP06_001_1007EN


5��1AP06_003_1007EN

Various methods of transporting your machine are possible. Loadingthe machine onto a transport vehicle is always one method. Theother methods depend on how your machine is equipped.− Machines with an F�80 chassis can travel on public highways.− The machine can be moved in the same way as a trailer if fitted

with an F�8 chassis, but movement is restricted to the constructionsite. The maximum speed at which it may be moved is 8�km/h. Themachine is not authorized for use on the public highway so you willhave to transport it to the construction site on a transport vehicle.

− The machine will always have to be transported on a transport ve�hicle if it has a static frame.

Lifting eyes will need to be fitted to the machine should you wish toload it onto a transport vehicle. Any lifting eyes fitted to your machinefor the purpose of lifting it will be located on the top of the machineand may be identified by their colour.

Suspended loadRaised loads may fall if they are not loaded properly or if the slingsand eyes are damaged.You should, therefore, never walk under suspended loads.

CautionThe machine may only be loaded by crane if it is equipped with suit�able lifting eyes. Lifting equipment, lifting tackle, support trestles andother auxiliary equipment must be reliable and safe in operation.Make sure that the loadbearing capacity is adequate. Always lift themachine by all its lifting eyes, otherwise too great a load could beplaced on individual lifting eyes.

The machine must be properly secured on the transport vehicle toprevent it rolling away, slipping or tipping over.

5.1 Transport

5.1.1 Loading


5��2 AP06_003_1007EN

Use the lifting eyes as shown.

NoteThe lifting eyes fitted to your machine for the purpose of lifting arelocated on the top of the machine and are marked by their colour(generally red).

It is best to transport the machine standing on its support legs sothat it cannot roll away.

AP06_003_1007EN 1

1

Suspend by all lifting eyes

1 Rope angle > 45_ �

" Hook a four−cable sling to the 4 lifting eyes.

DangerThe machine may begin to swing when weight is taken off the sup�port feet if it is hoisted at an angle. You must therefore always hoistthe machine vertically.

" Hoist the machine vertically.

" Place the machine on a suitable transport vehicle and lash itdown securely.

5.1.2 Lifting eyes


5��3AP06_003_1007EN

Suspended loadUse only appropriate lifting gear. Suspend the BSA from the liftingeyes specified.Never hoist the load over people. Take note of the safety regulationsfor crane operations.

AP06_003_1007EN 2

4 lifting eyes

BSA


5��4 AP06_039_1211EN

Your machine may be mounted on different chassis models or on astatic base structure, depending on the specification. The chassismodel is stated on the machine card and the maximum permittedspeed is stated on the rating plate.

The machine may not travel on public roads if fitted with an F�8 chas�sis. Towing the machine as a trailer is restricted to the constructionsite or private property.

CautionThe machine must not exceed a maximum speed of 8�km/h whenunder tow if fitted with an F�8 chassis.

You must load the machine onto a suitable transport vehicle to trans�port it to the construction site (see �Loading").

The machine may not travel on public roads if fitted with an F�25chassis. Towing the machine as a trailer is restricted to the construc�tion site or private property.

CautionThe machine must not exceed a maximum speed of 25�km/h whenunder tow if fitted with an F�25 chassis.

5.1.3 Chassis

5.1.4 F 8 chassis

5.1.5 F 25 chassis


5��5AP06_039_1211EN

The machine may travel on public roads in the same way as a stan�dard trailer if fitted with an F�80 chassis.

NoteStationary concrete pumps can only be driven on public roads if theyhave the appropriate approval. The driver of the tractor unit musthave the relevant driving licence.

If you have to drive in reverse you must always ask for a signaller toguide you. If necessary, have the route cordoned off or secured byassistants. Have the site management arrange for the removal of anymaterials or equipment that hinder your approach.

10000331

For hand signals, see the chapter �Hand signals for driving"

" Agree clear hand signals with the signaller before moving off.

5.1.6 F 80 chassis

Hand signals


5��6 AP06_039_1211EN

There are several tasks you will need to perform before joining thepublic road, including the following:

CautionIf you have changed the tyres, you must retighten the wheel nutsafter approximately 50�km.

See the spare parts sheet for the tightening torques.

" Check that the vehicle is safe to drive (lighting, brakes, tyreinflation pressures, wheel nuts etc.).

" Clean the machine so that it does not soil the public roads.

" Check that the accessories are secure.

DangerSupports extending spontaneously whilst the truck is moving cancause serious accidents. Fit the transport security devices (such asspring pins).

" Check to make sure that the support legs are secured fordriving.

" Observe the permissible gross laden weight.

" Check that the oil and water tanks are not leaking and that theyare securely closed.

Before moving off


5��7AP06_039_1211EN

The size and weight of the truck demand particular caution whendriving.

" Keep an adequate distance from slopes and pits.

" Only drive over arches, bridges or other supporting structuresif the load�bearing capacity is adequate.

" Be aware of the elevated position of the truck’s centre of gravitywhen travelling on a slope and on ascending or descendingroutes.

You must load the machine onto a suitable transport vehicle to trans�port it to the construction site (see �Loading").

Your machine can be towed by a tractor unit if fitted with a crawlertrack.

NoteObserve the manufacturer’s operating and maintenance instructions.

The machine is neither equipped nor approved for travel on publicroads.

If your machine is fitted with a stationary base structure, it can onlybe moved to the construction site on a transport vehicle.

During the journey

5.1.7 Crawler track

5.1.8 Static base structure


5��8 AP06_031_1007EN

It is often necessary to have a signaller help by directing you whenyou are driving to the set−up site on construction sites where spaceis restricted. Clear hand signals must be agreed between signallerand machine operator. Below you will find some suggestions forhand signals to be used when driving.

Extend both arms out to theside.

10000306

With the arm crooked, pointwith the thumb in the directionthe truck should steer.

10000301

With the arm crooked, pointwith the thumb in the directionthe truck should steer.

10000302

5.2 Hand signals fordriving

Stop

Drive to the left

Drive to the right


5��9AP06_031_1007EN

With the arm crooked, wave thepalm in the direction the truckshould drive.

10000303

With the arm crooked, wave thepalm in the direction the truckshould drive.

10000304

With the arm crooked, indicatethe distance to an obstacle withthe palms of the hands.

10000305

Drive towards thesignaller

Drive away from thesignaller

Clearance


5��10 AP06_005_1508EN

As a rule, the site management determines the set−up site for themachine and prepares the site accordingly.

NoteThe machine operator takes responsibility for setting up the machinesafely.

" Inspect the proposed site carefully and reject the set−up site ifyou have any doubts in respect of safety.

On stationary concrete pumps that are equipped with a system forexhaust gas treatment, regeneration procedures (stationary regener�ation) are regularly triggered automatically or, if required, activatedmanually.

Danger of fireDanger of fire due to inadequate clearance from a stationary con�crete pump during the regeneration procedure.During the regeneration procedure in particular, very high exhaustgas and surface temperatures occur near a stationary concretepump (approx. 600°C).Activate the regeneration procedure out in the open air only.Look for a set−up site that has sufficient clearance from other ma�chines, combustible materials and flammable liquids.Use your personal protective equipment.

5.3 Requirements for theset–up site


5��11AP06_005_1508EN

Danger of poisoningInjuries to the respiratory passage. Vehicle exhaust gases contain constituents that can be deadly orcarcinogenic.Set the machine up at an adequately ventilated site or vent the ex�haust gases away from where you are working.

" Ensure that the set−up site is adequately ventilated.

The set−up site must be level. It must be large enough for the ma�chine to be accessible for operation and maintenance work from allsides. You must be able to open all the guards, flaps and hoodswithout obstruction.

" Ensure that there is sufficient clearance around the entire ma�chine.

The approach route must be sufficiently firm that so it can be drivenover regardless of the weather conditions. Walk along the approachroute before you drive over it. Ask for a signaller if you need to re�verse.

The approach route to the concrete pump must be firm enough thatit can be driven over by truck mixers regardless of the weatherconditions.

There must be sufficient space around the concrete pump for truckmixers to manoeuvre and turn.

There must be sufficient space around the hopper for two truckmixers to unload at the same time.

Accessibility

Approach route

Space for truckmixers


5��12 AP06_005_1508EN

The supporting ground must be firm enough to absorb the forcesconducted by the support feet into the ground. There must not beany voids or ground unevenness under the support feet.

22102802

No voids or ground unevenness under the support feet

" Always rest the support feet on support plates, timber blocksor other suitable construction timber.

It is recommended that you select a set−up site which has been con�creted if the concrete pump is to remain on the same set−up site fora prolonged period.

It is recommend that concrete pumps working at high−pressure andhigh delivery rate are securely anchored.

Supporting ground


5��13AP06_005_1508EN

A minimum distance must be maintained from pits, slopes, excava�tions �etc. so that the machine cannot topple over.

45°

a

12100401

Minimum clearance a

The minimum clearance �a" for machines with a gross weight of upto 12 tons is 1 metre

" Maintain a distance from pits, slopes, trenches etc., when ap�proaching the set−up site.

The set−up site must be adequately illuminated in order to ensuresafe working on the machine.

" Ensure that the set�up site is adequately lit.

Draining of the washing water must be ensured (e.�g. using a sew�age pump), and particularly if the concrete pump has been set up ina pit or trench.

Minimum clearancefrom pits

Lighting

Draining away wash-ing water


5��14 AP06_016_0110EN

The machine must be level. Pay particular attention to the sectionheaded �Requirements on the set−up site".

" Drive the machine to the set−up site you have inspected.

AP06_016_0110EN 1

Initial situation

" Use chocks to secure the machine against rolling.

" Wind the support wheel down and disconnect the machinefrom the tractor unit.

AP06_016_0110EN 2

Lower the drawbar at the front

" Lower the drawbar as far as possible by winding up thesupport wheel.

5.4 Setting up


5��15AP06_016_0110EN

NoteYou must extend the support feet far enough so that the wheels willno longer be in contact with the ground when the machine is sup�ported.

AP06_016_0110EN 3

Supporting the rear

" Place timber blocks or other suitable material beneath the rearsupport feet.

" Unlock the rear support feet by removing the spring pins fromthe locking bolts and then removing the bolts.

" Extend the rear support feet as far as possible.

" Reinsert the locking bolts in the last possible hole and securethem with the spring pins.


5��16 AP06_016_0110EN

NoteUse only suitable lifting equipment for lifting the machine. Thesupport wheel is not suitable for lifting the machine.

AP06_016_0110EN 4

Raise the machine and support at the front

" Raise the machine by the drawbar sufficiently that the frontsupport feet can be extended to exactly the same extent as therear feet.

" Place timber blocks or other suitable material beneath the frontsupport feet.

" Unlock the front support feet by removing the spring pins fromthe locking bolts and then removing the bolts.

" Extend the front support feet to the same extent as the rearsupport feet and reinsert the locking bolts.

" Secure the locking bolts with the spring pins.


5��17AP06_016_0110EN

AP06_016_0110EN 5

Machine set up correctly

" Lower the machine.

NoteRecoil from the delivery line may be transmitted to the machineunder extreme operating conditions (high−pressure delivery, forexample). This recoil could jeopardize the stability of the machine.

The support feet can be anchored to the ground (concreting them inor lashing them down with tensioning chains, for instance) to give themachine greater stability.


5��18 AP06_014_1007EN

When pumping concrete, you must only use perfect and safe deliv�ery lines, couplings and seals. The delivery lines and couplings mustbe specially designed for the pressure specified on the pump ratingplate. The delivery lines are subject to wear, which is dependentupon:− the concrete pressure− the concrete composition− the delivery line material.

AP06_014_1007EN 1

10

9

87

5

43

2

6

1

No. 1 Designation

1 Pressure pipe2 Bolted coupling3 Reducer4 Clamp coupling5 Pipe bracket6 Delivery pipe (adapter pipe)7 Clamp coupling8 Pipe bracket9 Vibration damper

10 Delivery pipe (adapter pipe)

5.5 Stationarydelivery line


5��19AP06_014_1007EN

3�mAP06_014_1007EN 2

Danger zone for stationary delivery lines

DangerSerious injuries may be caused by the delivery line bursting as a re�sult of a sudden increase in pressure.Do not remain in the danger zone of a stationary delivery line.Cover the stationary delivery line with a metal casing or timber clad�ding if persons are working in its immediate vicinity.

AP06_014_1007EN 3

Cover delivery lines

5.5.1 Danger zone


5��20 AP06_014_1007EN

The stationary delivery line can be laid horizontally over the ground,or vertically or inclined against walls. The entire length of the deliveryline must be easily accessible and removable.

Note the following points when laying the delivery line:

" Lay the stationary delivery lines without stresses.

" Support the delivery line so that couplings can be easily fittedand removed. Double wooden chocks (see illustration) aremost suitable as they allow for longitudinal and latitudinalmovement by the delivery line.

AP06_014_1007EN 4

Support the delivery lines with double wooden chocks

" Use highly wear−resistant pipes for sections which are difficultto access.

" Begin laying the delivery line at the concrete pump as other�wise you will have to line up the concrete pump to the deliveryline.

5.5.2 Instructions for layingthe line


5��21AP06_014_1007EN

AP06_014_1007EN 5

Delivery line leading away at a right angle to the concretepump

" Route the stationary delivery line away from the concrete pumpat right angles to it. This minimizes the effect of pump pulsa�tions which may be transmitted from the delivery line to thepump and vice versa.

" Guide the delivery line in the direction of the arrow away fromthe concrete pump. The operator’s side of the concrete pumpis then not in the danger zone.

" Fit only as−new delivery pipes near the pump, as the concretepressure is highest here.

" Secure couplings against spontaneous opening.

" You must also take into account any components of the deliv�ery line required for distribution and cleaning such as a T−de�livery pipe with wash−out port, scraper pig gates, transfertubes, gate valves etc.


5��22 AP06_014_1007EN

Pump pulsations occur when pumping concrete. These are causedby the pump itself and are transmitted to the delivery line system.The stationary delivery line must be safely secured and stabilised onthe supporting ground.

DangerThere is a risk of serious injury from falling items.Do not secure the stationary delivery line to reinforcements or scaf�folding as these can be moved and could collapse.If you wish to secure the stationary delivery line to reinforcements orscaffolding, check whether the scaffolding can bear the load.

All horizontal delivery lines must be anchored on the supportingground.

" Use pipe brackets which are secured to a suitable supportingground capable of bearing the load� The pump pulsations are reduced and the delivery line isprevented from bending.

AP06_014_1007EN 6

Fastening the delivery line

5.5.3 Fastening

Horizontaldelivery line


5��23AP06_014_1007EN

A fixed point is a 1�−�2�m3 large, reinforced lump of concrete with adelivery pipe secured to it or sealed inside it. It takes pump pulsa�tions from the delivery line.

" Install a fixed point near to the concrete pump.� The pump pulsations are reduced and the delivery line isprevented from bending.

AP06_014_1007EN 7

Elasticity of the delivery line using a fixed point

Fixed point


5��24 AP06_014_1007EN

Vertical or angled delivery lines leading upwards or downwards mustalways be fastened to the structure or background so that they areself−supporting. The delivery line must not be supported by thelowest pipe bend.

AP06_014_1007EN 8

Fastening the delivery line

The lowest elbow should be a thick−walled 90° cast elbow with aradius of 1�m.

Vertical (angled)delivery line


5��25AP06_014_1007EN

The delivery line is called a riser where it is laid in such a way thatthe concrete is pumped upwards.

The weight of the concrete in the riser exerts a force on the concretepump (approximately 30�kg per metre of continuous pipe) when thepump is switched off.

" Install a gate valve at the start of the riser.� The delivery line can be closed off so that the pressurebears on the gate valve and not on the concrete pump.

The delivery line is called a downpipe if it is laid in such a way thatthe concrete is pumped downwards.

The concrete flows down through the delivery line under its ownweight when the pump is switched off. This causes the concrete col�umn to break off and the concrete can segregate.

" Install a gate valve at the end of the downpipe.� The delivery line can be closed off so that the concretecannot flow out of the delivery line.

Risers

Gate valve

Downpipes

Gate valve


5��26 AP06_014_1007EN

When laying Putzmeister SK delivery pipes, maintain a gap of 4�mmbetween the individual pipes.

NoteGrease all couplings and seals well internally before assembly. Usea lithium soap base multipurpose grease with the marking K2K.

4�mm

AP06_014_1007EN 9

Putzmeister SK delivery line with clamp coupling, A seal andspring pin

" Secure each clamp coupling with a spring pin.

5.5.4 SK delivery linesystem


5��27AP06_017_1008EN

The hydraulic hoses on the drive cylinder must be connected for rodside or piston side feed, depending on the job in hand. The machineis connected up for rod side feed when it is delivered.

The drive cylinders must be fed on the rod side to pump a largequantity of concrete in a short time.

The drive cylinders must be fed on the piston side to pump concreteat high pressure.

Danger of explosionPiston side feed gives a higher concrete pressure. You must there�fore only use delivery lines suitable for high−pressure delivery if youare using piston side feed.

The procedure for changing the feed to the drive cylinders is as fol�lows:

" Shut the machine down and secure it against unauthorized oraccidental starting.

" Dump the pressure in the hydraulic system and in the accumu�lator completely before you start working on the hydraulic sys�tem.

CautionCleanliness is of the utmost importance in the maintenance of hy�draulic systems. Prevent any type of dirt and contamination fromentering the system. Even small particles of dirt may cause valves tobe scored, pumps to seize and throttle and control bores to becomeblocked.

5.6 Rod side – piston sidefeed

Normal delivery

High–pressuredelivery

Changing over


5��28 AP06_017_1008EN

AP06_017_1008EN 1

1 2

No. 0 Designation

1 Rod side feed2 Piston side feed

" Place a container beneath the ports you are changing over tocatch the fluid.

Environmental protection All functional fluids and operating materials, e.g. oils (including bio�logically degradable oils), filters and auxiliary materials must becarefully collected and disposed of separately, both from each otherand from other waste. Different categories of oil must also be keptseparately from each other. Nationally and regionally applicable dis�posal regulations must be observed for these materials.

" Change over the hydraulic hoses as illustrated.

DangerOnly top up with new hydraulic fluid.

" Top up the hydraulic fluid in the hydraulic fluid reservoir by thesame amount that has escaped.


5��29AP06_056_1008EN

Depending on the machine specification, it may be equipped witheither a Hypro WP 50 or a CRK 4−160.

NoteThe water supply can be hampered by:� the water hose diameter being too small� the water pressure being too low for a significant head� the hoses being pinched or kinked� a damaged hose or� several consumers using the same water supply at once

AP06_056_1008EN 1

2

1

No. 0 Designation

1 Claw coupling for high−pressure water hose2 Claw coupling for the water supply

NoteMake sure that you connect the flushing water pump with a sufficientsupply of water (50�litres per minute).

5.7 Flushing water pump

Flushing water pumpHypro WP 50


5��30 AP06_056_1008EN

2

AP06_056_1008EN 2

1

2

No. 0 Designation

1 Claw coupling for high−pressure water hose2 Claw coupling for the water supply

NoteMake sure that you connect the flushing water pump with a sufficientsupply of water (160�litres per minute).

Flushing water pumpCRK 4–160

Pumping�operations

6��IAP07_026_9710EN

6 Pumping operations

This chapter contains information regarding the operation of themachine for pumping. You will learn what steps are required forpumping and cleaning.


6��II AP07_026_9710EN


6��1AP07_069_1007EN

You must have carefully completed the operations required to startup and set up the machine before you start pumping.

Before you fill the hopper with concrete and pump it through thedelivery line, make sure that:− the machine is functioning,− the delivery line is designed to withstand the relevant concrete

pressure and− the delivery line is correctly laid.

NoteIf a malfunction occurs during the pumping operation, you must stopyour work and have the cause of the fault rectified by qualified per�sonnel at your company or by our After Sales Service personnel.

Timely detection and rectification of damage can prevent lengthydowntimes and high repair costs.

6.1 Preconditions


6��2 BP07_051_1109EN

Depending on your machine’s equipment, you can operate it− with the radio remote control,− with the cable remote control or− directly on the machine in emergency operation.

CautionCarry the remote control in such a way that no control elementscan�be actuated unintentionally. Do not damage the remote controlcable. Malfunctions may otherwise occur.Never put the remote control down when the machine is ready foroperation. If this is unavoidable in exceptional cases, you mustswitch off the remote control, disconnect it and lock it away.

DangerRisk to life from unintended machine movements. The range ofa�radio remote control is great enough for the machine to receivecontrol commands (e.g. from a great distance, from inside enclosedspaces), even without visual contact. In such cases, signallers MUSTbe used, and must remain in contact with the machine operatorusing suitable means, and have visual contact with the site ofconcrete placement, work and danger zones and the machine.

6.1.1 Remote control


6��3AP07_029_0905EN

It is particularly important that the machine operator at the concretepump and the concreting gang working at the placement site cancommunicate with each other if accidents are to be avoided whenpumping. Communication is particulary important in long−distanceand high−rise pumping where the machine operator cannot see thesite of concrete placement. Communication may be via unambiguousand non−interchangable:− acoustic signals such as a horn, two−way radio, field telephone

etc.− optical signals such as light signals, hand signals etc.− a combination of optical and acoustic signals

Suggestions for the most important hand signals are made in thischapter. They are based on DIN�24081, DIN�33409 and guidelineRI/08.90/2 issued by the German Construction Employers’ LiabilityInsurance Association, amongst other guidelines. The direction ofmovement is specified from the machine operator’s direction of view.

Extend both arms outwardsand move up and downquickly.

10000308

Place a fist on the helmet.

10000307

6.2 Hand signals forpumping

EMERGENCY STOP

Slow


6��4 AP07_029_0905EN

The thumb of one hand pointsupwards. The palm of theother hand is held over it.

10000327

The thumb of one hand pointsdownwards. The palm of theother hand is held under it.

10000328

The crooked elbow of one armpoints downwards into thepalm of the other hand.

10000329

Grip both hands together overthe head.

10000330

Increase output/Start pumping

Reduce output

Reverse pumping

Stop pumping


6��5AP07_080_1501EN

Your machine is driven by a diesel engine. The fuel tank is integratedinto the truck superstructure, and its filler pipe is located on the leftside of the machine. You can use the filler opening to refuel the ma�chine when it is switched off.

NoteRefill the fuel tank in good time, as otherwise you will have to bleedthe fuel line to the diesel engine.

The engine and its exhaust after treatment system are coordinatedwith one another and form a complete engine system.

CautionDamage to the complete engine system by not complying with theengine manufacturer’s requirements and recommendations for func�tional fluids.Diesel engines equipped with SCR, DPF and DOC types of exhaustafter treatment systems must only be filled and operated with sul�phur−free diesel (in accordance with DIN�51628 and EN�590).Failure to observe this means that the engine manufacturer cannotguarantee the operational safety and life of the exhaust after treat�ment system.Only fill the machine with fuel when the engine is switched off.Pay attention to cleanliness when filling the machine with fuel. Do notspill a single drop of fuel.Observe the requirements and recommendations for operating ma�terials such as lubricating fluid, permitted fuels, coolant and dieselexhaust fluid in the engine manufacturer’s documentation.

6.3 Filling the machinewith fuel


6��6 AP07_077_1501EN

This machine is fitted with an exhaust after treatment system. Ex�haust gas is treated using a diesel exhaust fluid (DEF), e.g. �Ad�Blue". Once the warning symbol �Fill level of the DEF container"lights up yellow, fill the DEF container via the filler opening (see theengine manufacturer’s documentation).

NoteFill up the DEF container in good time (when the �Fill level of the DEFcontainer" warning symbol lights up yellow) to prevent the enginepower from being reduced.

CautionDamage to the SCR system caused by diesel exhaust fluid (DEF)impurities.Impurities in other media (e.g. diesel) damage the SCR system.Dilution of the diesel exhaust fluid impairs DEF quality and exhaustgas treatment, and therefore reduces the power of the engine (seeengine manufacturer’s documentation).Only fill the DEF container when the engine is switched off. Ensurecleanliness.Only fill the DEF container with diesel exhaust fluid specified by theengine manufacturer, because otherwise the DEF quality and ex�haust gas treatment will become poor.

6.4 Filling the DEF con-tainer


6��7AP07_077_1501EN

CautionDanger of burning when handling diesel exhaust fluid.Diesel exhaust fluid is an ultra−pure urea solution that has a causticeffect on the skin and eyes.Use your personal protective equipment when handling diesel ex�haust fluid.Avoid skin contact with diesel exhaust fluid. Any residue must bewashed off with water.

CautionCorrosion damage and damage to electrical and electronic compo�nents within the engine compartment caused by contact with DEF.Fill the DEF container carefully so that the engine compartment is notcontaminated with DEF. Contaminated components must be washedwith water.


6��8 AP07_077_1501EN

AP07_077_1501EN 1

1

2

Example illustration: Filling the DEF container

Pos.0 Designation

1 Fill level warning symbol for the DEF container (yellow)2 DEF container


6��9AP07_077_1501EN

AP07_077_1501EN 2

1

2

Example illustration: DEF container

Pos.0 Designation

1 DEF container2 Lid

" Switch off the remote controls.

" Switch the pump off.

" Switch the diesel engine off.

" Secure the machine against being started up unintentionally.

" Unscrew the lid�(2) from the filler opening of the DEF con�tainer�(1).

" Fill the DEF container�(1) with diesel exhaust fluid.

" Screw the lid�(2) back onto the filler opening of the DEF con�tainer�(1).


6��10 AP07_031_0304EN

Properties of the concrete such as its consistence and grading curveare decisive factors for the optimum fill level of the delivery cylinders.The fill level influences the level of efficiency of the pump, i.e. theoutput per stroke.

11000401

12

3

No. 0 Description

1 Aggregate2 Cement paste3 Boundary layer

NoteA low fill level will be achieved in the delivery cylinder if the consist�ence is too stiff and the grading curve of the aggregates is unfavour�able (low sand content, broken material). In such cases, reducingthe speed of pumping can increase the output.

6.5 Considering concreteproperties

Saturated mix


6��11AP07_027_0303EN

AP07_027_0303EN 1

Always fill the agitator hopper with concrete up to the mixer shaft.

DangerEntrapped air in the delivery line is dangerous as the compressed airis released suddenly at the end of the delivery line and the concretecan be blown out explosively. No air must be sucked in for thisreason.

You should therefore always fill the agitator hopper with concrete upto the mixer shaft during pumping operations.

AP07_027_0303EN 2

Danger from escaping compressed air

6.6 Filling the agitatorhopper


6��12 AP07_032_9710EN

The process from the start of forwards pumping to the time at whicha continuously flowing concrete stream exits from the delivery line isknown as starting to pump. This may be at the start of the site use, oralso after breaks in pumping.

The entire delivery line must be wetted at the start of pumping oper�ations.

11000501

Starting pumping with thin concrete

" Insert two sponge balls into the delivery line through thewash−out port.

" Pour approximately 0.5 m3 thin concrete into the hopper.

" Switch the agitator on.

" Slowly pump the concrete into the delivery line.

Starting to pump with thin concrete is completed when the twosponge balls and a solid concrete stream exit from the delivery line.

NoteYou must begin pumping with a cement−water mixture (grout) if thedelivery lines are new, or if the delivery line has not been used for along time.

6.7 Starting pumping


6��13AP07_034_9710EN

Correct mixing of the concrete influences pumping performance.

" Mix the concrete vigourously in the truck mixer at maximumspeed. Ensure that the concrete mix is uniformly prepared.

" Concrete additives (deflocculants, set retarding admixtures)must be mixed in for at least 4�minutes after they are added.

" Pour the concrete from the truck mixer, silo, etc into the agitatorhopper.

" Switch the agitator on.

" Begin delivery.

NoteStart with a low output and increase this continuously after severalcubic metres.

A machine driven by a diesel engine can be run more economicallyby selecting engine speed and output regulation such that theengine does not rev too highly when under low load.

6.8 Pumping


6��14 AP07_035_9710EN

The displays of the monitoring instruments must be kept underobservation during pumping operations.

10301100

1 2

3

No 0 Designation

1 Vacuum meter2 Hydraulic fluid temperature gauge3 Hydraulic pressure gauge

" Check all displays for the monitoring instruments:

− Vacuum meter: the indicator must not be in the red zone. An indi�cator in the red zone implies that the associated vacuum filter iscontaminated or the hydraulic fluid is too cold.

− Fluid temperature gauge: the fluid temperature must not exceed90�_C.

− Hydraulic pressure gauge: the value indicated must not exceedthe maximum value specified on the machine card.

6.8.1 Monitoring


6��15AP07_035_9710EN

NoteYou must repeat these checks at regular short intervals all the timethe machine is running.

DangerThe machine must be switched off every time a fault is indicated. Allfaults must be rectified immediately, otherwise the guarantee will beinvalidated.

" Check the bearings and seals on the switching shaft, the pres�sure connection and the agitator shaft at regular intervals.

" Lubricate the machine as required.

NoteThe bearings and seals must be replaced as soon as a cement−coloured fluid and grease mixture or slurry begins to escape.


6��16 AP07_037_9710EN

11000601

1 2

3

No 0 Designation

1 Wedged aggregate2 Cement paste3 Boundary layer

The following faults can lead to blockages:− delivery line is insufficiently wetted− transfer tube is leaking− lines are leaking− leavings in the transfer tube and delivery line− unsuitable concrete composition− segregated concrete− set concrete

CautionIn the event of blockages, pump the concrete immediately back intothe agitator hopper and mix it up. You can switch over to forwardspumping when the delivery cylinders and the transfer tube areswitching over automatically again without problem. Begin pumpingagain with care.

6.8.2 Blockages


6��17AP07_038_9710EN

You should avoid breaks in pumping as far as possible, as the con�crete in the delivery line can start to set, or can become segregateddue the the vibrations of the machine. Note the following points ifbreaks are unavoidable:− Never leave the delivery line under pressure.− Relieve the delivery line during short breaks in delivery by reverse

pumping briefly (2−3 strokes). Move the concrete at short intervalsby forward and reverse pumping.

− You should avoid breaks when pumping concrete with a low waterretentivity (tendency to bleeding) as the vibrations can segregatethe concrete. You must always leave the pump switched to reversepumping when you begin pumping again and wait for the transfertube to switch across fully on both sides. Only then can you switchover to forwards pumping again.

− Pump the concrete back into the agitator hopper before longbreaks in pumping. You must mix the concrete again before yourecommence pumping.

NoteReverse pumping is only possible for a few pump strokes, otherwisethe hopper overflows.

CautionNever use force to pump segregated concrete or concrete that hasbecome lumpy because it is beginning to set into the delivery line.Blockages can very easily be caused in this way.

6.8.3 Breaks in pumping


6��18 AP07_056_0304EN

Do not exceed the permissible engine speed specified in the ma�chine card and on the machine rating plate. Always set the enginespeed higher than the vibrating speed. Do not shut down the engineimmediately after periods of heavy engine loading, but first allow it tocool down at idling speed.

During normal pump operation, the temperature of the hydraulic fluidis between 70�_C and 80�_C.The following may cause the hydraulic fluid to overheat, particularlyif�several factors coincide:− continuous operation under high load− high ambient temperatures− too little fluid in the hydraulic system− dirty hydraulic fluid radiator− insufficient radiator ventilation− hydraulic fluid radiator sucking in hot exhaust gases− excess pressure as a result of a blockage− too little water in the water box.

All pumps have a thermo−electrical cut−out. The pump is automati�cally shut down if the fluid heats up to over 90�_C. The engine keepsrunning to provide cooling and a red indicator lamp lights up on thecontrol cabinet. Proceed as follows to prevent a shut−down in themiddle of pumping when a fault is indicated:

" Reduce the output.

" Fill the water box with fresh water as soon as the fluid tempera�ture rises above 80_C.

6.8.4 Engine

6.8.5 Overheating


6��19AP07_056_0304EN

10600200

" Change the water frequently if the temperature continuesto�rise.

" Trace the cause of fluid overheating and rectify it.

If necessary, you can cool the drive cylinders with a water jet if themeasures described above are not adequate.

10600400

" Direct the water jet at the drive cylinders and piston rods forthe drive cylinders.

CautionNever use sea water or salt water for cooling. Otherwise the chromelayer on the delivery piston rods and delivery cylinders will bedestroyed.

Cooling

Additional cooling


6��20 AP07_081_1501EN

This section describes how to operate the exhaust after treatmentsystem.

DangerRisk of burning when touching components that conduct exhaustgases.Particularly during the DPF regeneration procedure/stationary regen�eration, extremely high exhaust gas and surface temperatures ariseat the exhaust after treatment system.You are not permitted to use the machine during stationary regener�ation.Maintain a sufficient distance from the exhaust after treatment sys�tem. Use your personal protective equipment.

NoteRefer to the engine manufacturer’s documentation for details on howto work and handle the exhaust after treatment system (also see the�Exhaust after treatment system" section in the �General technicaldescription" chapter).

NoteThe warning strategy of the SCR system complies with the relevantnational codes of practice.The following emission−relevant faults are therefore displayed:� Fill level of the DEF container� DEF quality and exhaust gas treatment� DPF regeneration� Manipulation(See the �Menu−independent warnings" section in the chapter �Gen�eral technical description").

6.8.6 Exhaust after treat-ment system


6��21AP07_081_1501EN

The diesel particulate filter (DPF) with passive regeneration continu�ously regenerates automatically (without the user having to do any�thing) if the filter load has reached 100% of the nominal soot load.The continuous DPF regeneration procedure takes approx. 40 min�utes with exhaust gas temperatures of approx. 580 °C at the DOC/DPF module.

You can switch off/prevent the DPF regeneration procedure at thefuse box as follows; for example, if the machine is located in a lowbuilding:

" Press the �DPF regeneration On − Off" toggle switch again orswitch the �Pumping operations/Enable DPF regeneration"toggle switch from the �Enable DPF regeneration" switch posi�tion to �Pumping operations".

NoteIf you interrupt a DPF regeneration, the diesel particulate filter con�tinues to be loaded. As soon as the message text �DPF regenerationrequired" is displayed in the EGD, you must manually switch on DPFregeneration.

Automatic DPF regen-eration


6��22 AP07_081_1501EN

If the filter load has reached 100% of the nominal soot load on thediesel particulate filter (DPF), DPF regeneration is required.A yellow �DPF regeneration" warning symbol lights up in the EGD,along with the message text �DPF regeneration required". The DPFregeneration/stationary regeneration must be switched on manually.DPF regeneration lasts approx. 40 minutes and takes place at ex�haust gas temperatures of approx. 580 °C at the DOC/DPF module.

Danger of fireDanger of fire due to an inadequate clearance from a stationary con�crete pump during the DPF regeneration procedure.During the DPF regeneration procedure in particular, very high ex�haust gas and surface temperatures occur near a stationary con�crete pump.Only activate the DPF regeneration procedure out in the open.Look for a set−up site that has sufficient clearance from other ma�chines, combustible materials and flammable liquids.Use your personal protective equipment.

NoteIf you interrupt a DPF regeneration procedure due to a yellow �DPFregeneration" warning symbol, the exhaust after treatment systemwill activate further escalation levels (depending on the length of thepumping operation).The result is that power reduction level�2 is activated in the last es�calation level if there is a red �DPF filter maintenance required" warn�ing symbol. Pumping operations and DPF regeneration are disabled.A service employee of the engine manufacturer must replace theDPF filter.The engine can only be enabled using service software from the en�gine manufacturer (SERDIA service tool).

Stationary regener-ation


6��23AP07_081_1501EN

NoteThe engine oil becomes diluted with fuel after each stationary regen�eration. The quality of the engine oil is monitored for this reason.The engine oil must be changed as soon as the yellow �Engine oilchange required" warning symbol lights up in the EGD.

NoteWhen the �DPF regeneration" warning symbol lights up in yellow inthe EDG of the �OPS/EDG control cabinet", you need to start the re�generation procedure/stationary regeneration �manually" at the fusebox.The regeneration procedure can only be started �manually" if the fol�lowing conditions are met:� You have positioned the machine in the open, on terrain with a

sufficient distance from other machines, combustible materialsand flammable liquids.

� The engine speed must be lowered to idling speed.� Output must be reduced to 0%.� The engine must be in a no−load condition.� The engine must be warm (coolant temperature higher than 70 °C

and exhaust gas temperature downstream of the DOC lower than250 °C).

� The SCR system to reduce nitrogen oxide (NOx) must be active.� The �Fill level of the DEF container" warning symbol must display a

value higher than 15%.� The DEF container must not be frozen.

Once all the conditions listed above have been met, you can startthe DPF regeneration procedure at the DPF fuse box.The DPF regeneration procedure takes approx. 40 minutes.

You can switch on the DPF regeneration procedure at the fuse boxas follows:

" Switch the �Pumping operations/Enable DPF regeneration"toggle switch from the �Pumping operations" switch position to�Enable DPF regeneration".

" Press the �DPF regeneration On − Off" toggle switch to the�DPF regeneration on" switch position


6��24 AP07_058_0303EN

Proceed as follows if the pump has nevertheless switched offbecause of overheating:

" Set the output controller to �min".

NoteNever switch the engine/motor off, as the radiator must remain inoperation.

" Refresh the water in the water box.

" Wait until the fluid has cooled if you are not able to find the faultimmediately.

" Once the red indicator lamp has extinguished, switch thepump back on and continue pumping slowly at reducedoutput.

" Determine the cause of the fluid overheating once pumpingoperations have been completed and rectify the fault.

6.8.7 Restarting


6��25AP07_040_1009EN

Concrete leavings that are deposited inside the delivery line ortransfer tube can cause damage, will accumulate and reduce thecross section. A clean delivery line and transfer tube is therefore in�dispensable if you wish to be able to start pumping without problemson the next job.

Concrete leavings deposited around the wear ring can impair itsfunction. For this reason, thorough flushing of the wear ring is re�quired at the end of a job, unless the next pumping job follows within30�−�60�minutes.

Cleaning instructions

CautionTo ensure that you do not damage the paint and other surfaces ofyour machine, you must observe the following:� Never use sea water or other water containing salt for cleaning

purposes. You must rinse off any sea water that is deposited onthe machine.

� Do not use any aggressive cleaning agents.� The water used for washing must not be hotter than 50 °C

(122�°F).� The spray nozzle must be held at least 40�−�50�cm from the paint

surface.

You must also observe the following during the first 8�weeks of oper�ation:� During this time, you must not use any steam jet equipment since

the paint is not fully cured.� Furthermore, you may only use cold water for cleaning during this

period.

Lock the remote control unit away during cleaning operations. Theremote control unit does not have a watertight casing. Perform themachine functions required during cleaning operations from the con�trol cabinet.

6.9 Cleaning


6��26 AP07_040_1009EN

You should always find an appropriate use for the concrete leavingsto help in environmental protection.

Environmental protectionThe concrete leavings should be used on the construction site. If thisis not possible, the concrete leavings should be used as buildingrubble or be recycled.

We recommend that you use the Putzmeister �Leavings sheet" toallow you to make use of the concrete leavings. You can lay thisdown under the hopper before opening the hopper flap. The con�crete then flows out into the sheet and can be transported to the siteof concrete placement using a site crane.

If the concrete is not to be used, you should bend a length of rein�forcing steel into a hook and insert it in the concrete. Once the con�crete has set, you can transport the lump of concrete away using asite crane.

Concrete leavings


6��27AP07_040_1009EN

DangerLeave the agitator grille closed during all cleaning operations, sinceyou could be caught by the agitator.

The automatic agitator cut−out must operate correctly if it is never�theless necessary to open the grille.

Due to technical reasons, the hopper flap at the bottom of thehopper cannot be secured. There is a risk of injury by crushing orloss of limb by shearing if you reach inside. It is prohibited to reachthrough the hopper flap into the hopper from below.

AP07_040_1009EN 1

Do not reach into the hopper.

Compressed air cleaning

DangerThere is an increased risk of accident when cleaning with com�pressed air. The cleaning operation must only be carried out by aspecialist or under expert supervision. Putzmeister accepts no liabil�ity for damage caused by cleaning with compressed air, if performedincorrectly. All persons participating in the cleaning procedure mustbe instructed in the safety regulations.


6��28 AP07_041_9712EN

We recommend that you carry out the preparations described belowin good time to allow you to clean the delivery line and the concretepump directly the site use is completed.

10003401

1

2

3

4

1 Sponge pig2 Sponge cube3 Sponge ball4 Wash−out pig

You will need sufficient numbers of sponge balls and other cleaningaccessories to clean the machine properly.

6.9.1 Preparationsfor cleaning

Sponge balls andother�accessories


6��29AP07_041_9712EN

You must use the catch basket if you wish to force the concrete outof the end of the pipe using water pressure or compressed air. Itmust be designed such that the concrete can flow out unhindered,but that the sponge ball (cube, pig) is trapped and that this simulta�neously seals off the delivery line.

DangerA catch basket on the end of the delivery line is an absolute require�ment if you are forcing the concrete out using compressed air, asotherwise there is a risk of injury from the wash−out sponge andconcrete as they are expelled.

The use of the catch basket is recommended when water is used toforce out the concrete to ensure that the delivery line is sealed offand no water can escape.

31201501

1

2

3

4

1 Coupling2 Catch basket (closed pipe section)3 Spring pin (on both sides)4 Catch bracket

Catch basket


6��30 AP07_041_9712EN

The wash−out adaptor is used when the machine is cleaned usingwater under pressure or compressed air.

DangerThe wash−out adaptor must not be fitted to the delivery line whilepump is running as the wash−out connections and shut−off valvesare not designed to withstand the pressure of the concrete pump.The cleaning connection can only be used for cleaning up to a maxi�mum water or air pressure of 10�bar.

A catch basket on the end of the delivery line is an absolute require�ment if you are forcing the concrete out using compressed air, asotherwise there is a risk of injury from the wash−out sponge andconcrete as they are expelled.

31201503

1

6

5 4 3

2

1 Pressure gauge2 Guard bracket3 Connection for water under pressure or compressed air4 Shut−off valve for connection5 Pressure dump bend6 Dump cock

Wash−out adaptors


6��31AP07_041_9712EN

The T−delivery pipe with wash−out port can be used when cleaningwith water under pressure. It allows the wash−out sponges to beinserted quickly.It traps the wash−out sponge in suction cleaning.

AP07_041_9712EN 1

12

1 T−delivery pipe with wash−out port2 Wash−out port lid

DangerMake sure that the T−delivery pipe is also designed for the pressurestated on the pump rating plate.

You must only open the wash−out port lid once the pressure in thedelivery line has been dumped.

T−delivery pipe withwash−out port


6��32 AP07_041_9712EN

Cement bags soaked in water and rolled up have proved usefulwhen cleaning the delivery line using water under pressure. Thecement bags prevent the washing water penetrating the concrete,flushing the concrete out and causing blockages.

10003501

Rolled−up cement bags

" Roll up 1 − 2 empty cement bags together.

" Immerse the rolled−up cement bags in water for about5�minutes before starting the cleaning operation.

NoteYou may also prepare a short pipe section containing the cementbags and a wash−out sponge before you start the cleaning oper�ation.

10003502

Cement bags forhigh−pressurewater�cleaning


6��33AP07_041_9712EN

The best way to clean the wear ring and seal ring on the transfertube is to rinse this area with water for some time from close up. Youmust mark the water hose as described below to ensure that thehose does not get cut by the switching transfer tube during cleaning.

DangerThe machine must be switched off and the hydraulic system, includ�ing the accumulator, fully depressurized when you are measuring thehose length required, as otherwise there is a risk of injury as thetransfer tube switches over.

AP07_041_9712EN 2

1

1 Adhesive tape marking

" Measure the hose length required on the outside of the transfertube. The nozzle on the hose should be located shortly beforethe seal ring so that concrete leavings are washed away fromthe area around the wear ring and seal ring when the nozzle isset to spray.

" Mark the measured length on the hose with adhesive tape, orsimilar.

Mark the water hose


6��34 AP07_042_9712EN

There are a number of options for cleaning a delivery line. Some ofthe factors affecting which cleaning method you use include how theconcrete pump has been used and what equipment you have avail�able.

Overleaf you will find a summary showing which cleaning methodis�recommended for the delivery lines listed. The symbols used inthe summary are explained below. The cleaning procedures aredescribed in the following sections.

The delivery line is connected to the concrete pump.The leavings are pumped by the concrete pump out ofthe hopper and onwards to the site of concrete place�ment. Cleaning is from the hopper onwards to the siteof concrete placement.

The delivery line is connected to the concrete pump.The leavings are sucked back by the concrete pumpfrom the site of concrete placement into the hopper.Cleaning is backwards from the site of concrete place�ment to the hopper.

The delivery line has been disconnected from the con�crete pump. The leavings are forced forwards from thestart of the delivery line to the site of concrete place�ment using an external force (compressed air or waterunder pressure). Cleaning is from the start of the deliv�ery line to the site of concrete placement.

The delivery line has been disconnected from the con�crete pump. The leavings are forced backwards fromthe site of concrete placement to the start of the deliveryline to using an external force (compressed air or waterunder pressure). Cleaning is from backwards from thesite of concrete placement to the start of the deliveryline.

Recommended method of cleaning

Method of cleaning not recommended

Prohibited method of cleaning

Method of cleaning not possible

6.9.2 Delivery line

How to clean whichdelivery line


6��35AP07_042_9712EN

Overview of the cleaning procedures for the stationary delivery line

Delivery line

Leavingsfrom

to

Method ofcleaning

Compressed air

Horizontal line Water under pressure

Suction cleaning

Compressed air only withspecial

Riser Water under pressurespecialequipment

Suction cleaning

Compressed air only withspecial

Downpipe Water under pressurespecialequipment

Suction cleaning


6��36 AP07_043_9712EN

Suction cleaning is the simplest and least hazardous method ofcleaning a riser. The method is described below.

" Pump the agitator hopper out until the concrete is at the levelof the top of the delivery cylinder tubes.

" Then switch the pump off.

12500100

Inserting a water−soaked wash−out sponge

" Push a water−soaked wash−out sponge (cube) into the end ofthe delivery line at the site of concrete placement.

" Switch the pump to reverse pumping.� The concrete and the wash−out sponge are pumped backthrough the delivery line.

AP07_043_9712EN 1

Tapping on the delivery line with a hammer handle

" Tap on the delivery line with a piece of hardwood (hammerhandle) just ahead of the cleaning eye during the washing outprocess.

Suction cleaning

Check for thewash−out�sponge


6��37AP07_043_9712EN

NoteTapping produces deep dull noises there is concrete in the deliveryline. Tapping will yield high, clear sounds as soon as the concreteand wash−out sponge have passed the point at which you aretapping.

Use only a hammer handle to tap on the delivery line, as otherwisethe pipe may be damaged.

" Switch the pump off as soon as the wash−out sponge haspassed the point at which you are tapping.

AP07_043_9712EN 2

Turn the wash−out port lid round

" Open the wash−out port on the T−delivery pipe, turn thewash−out port lid round and close it again with the pin pointinginwards.

" Switch the pump back to reverse pumping.� The wash−out sponge will be trapped on the pin of thewash−out port lid.

" Then switch the pump off.

" Open the wash−out port lid and remove the wash−out sponge.

" Repeat the washing out procedure, as a single reverse pump�ing pass of a wash−out sponge is not sufficient.

Trapping thewash−out�sponge


6��38 AP07_045_9712EN

High−pressure water cleaning, which is more thorough, but moretime−consuming than suction cleaning, is described below.

" Pump out the agitator hopper as far as possible.

" Switch the pump over to �Reverse pumping" and relieve thepressure on the delivery line by 1 or 2 strokes of reversepumping.

" Switch the pump off.

AP07_045_9712EN 1

1 2

1 Prepared pipe section for cleaning2 Wash−out sponges being introduced

" Push two or three water−soaked wash−out sponges into thewash−out port and close the port or fit the pipe section pre�pared for cleaning into the delivery line.

" Hose down the hopper with water.

" Fill the agitator hopper with water.

" Switch the pump to �Forwards pumping".� The water forces the concrete in the delivery line towardsthe end of the delivery line.

" Top up the water in the hopper in good time (on longer deliverylines) before air is sucked in.

" Pump until the wash−out sponges exit at the end of the deliveryline. Take care to ensure that the water flowing behind it doesnot run into the formwork.

" Then switch the pump to reverse pumping so that the washingwater can flow out of the delivery line.

High–pressurewater cleaning

Introducing thewash−out sponge


6��39AP07_046_9712EN

The principle of this method of cleaning is similar to that for high−pressure water cleaning. This involves, however, separating thedelivery line from the concrete pump and replacing this with anauxiliary pump such as a high density solids pump (KOV) or awash−out adaptor with high−pressure water pump.

NoteAny high−pressure water pump you might be using must have asufficient volumetric flow rate of water.

" Pump out the agitator hopper as far as possible.

" Switch the pump to �Reverse pumping" and relieve the pres�sure on the delivery line by 1 or 2 strokes of reverse pumping.

" Switch the pump off and then remove it from the delivery line.

" Now attach the auxiliary pump to the delivery line or use thewash−out adaptor with high−pressure water pump.

Cleaning with anauxiliary pump


6��40 AP07_046_9712EN

AP07_046_9712EN 1

1 2

1 Prepared pipe section for cleaning2 Wash−out sponges being introduced

" When using an auxiliary pump, push two or three water−soaked wash−out sponges into the wash−out port and closethe port or fit the pipe section prepared for cleaning into thedelivery line.

" When using a high−pressure water pump, push two or threewater−soaked wash−out sponges into the wash−out port andthen connect it to the delivery line.

" Connect the water for the auxiliary pump or high−pressurewater pump.

" Switch the pump to �Forwards pumping".� The water forces the concrete in the delivery line towardsthe end of the delivery line.

" Pump until the wash−out sponges exit at the end of the deliveryline. Take care to ensure that the water flowing behind it doesnot run into the formwork.

Introducing thewash−out sponge


6��41AP07_047_9904EN

One possible method of cleaning the hopper, the delivery cylinderand the S transfer tube is described below.

NoteIf the machine is fitted with an agitator safety cutout, the agitator ishalted and the transfer tube no longer switches over as soon as youopen the grille. In addition, the delivery pistons return to the endposition and the concrete pump halts. You must close the grille torestart the concrete pump.

DangerIn no event should you insert the water hose, the spray gun or otherobjects through the grille into the hopper to spray out the deliverycylinders. Such objects may be trapped by the transfer tube as itswitches over and become damaged. The objects may be caused tofly about, thereby causing an injury to you or other persons.

AP07_047_9904EN 1

ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ

Lay the sheet down

" Place the Putzmeister leavings sheet beneath the hopper.

" Open the hopper flap beneath the hopper and let the leavingsflow out of the hopper.

6.9.3 Hopper, deliverycylinder andS transfer tube

Drain off the leavings


6��42 AP07_047_9904EN

" Switch the pump over to reverse pumping.� This pumps the leavings out of the delivery cylinders intothe hopper and thus out of the hopper opening.

30000500

Hoisting the concrete away

CautionYou may only hoist a maximum of 0.5�m3 concrete (approxi�mately�1200�kg) using the Putzmeister leavings sheet.

" Hoist away the concrete in the Putzmeister leavings sheet.


6��43AP07_047_9904EN

AP07_047_9904EN 2

ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ

Spray out the transfer tube and delivery cylinder with the concrete pump running slowlyin reverse

" Allow the concrete pump to run slowly in reverse.

" Spray the transfer tube out carefully downwards from the pres�sure connection. Slowly insert the hose up to the marking asyou do this (see the �Mark water hose" section).

Spray out deliverycylinder


6��44 AP07_047_9904EN

AP07_047_9904EN 3

Insert the water hose into the transfer tube as far as the marking

" Hold the water hose in this position, introduced as far as themarking, for several minutes, until only clean water runs out.� This will flush out the two delivery cylinders alternately.

" Carefully spray out the hopper using a hose.

" Hose down all components that have come into contact withconcrete.


6��45AP07_047_9904EN

You should check the seal gap between the transfer tube and wearring following cleaning. The gap �S" must be 1.5 to 2�mm, if not thetransfer tube must be readjusted.

Maintenance card: Adjusting the S transfer tube

AP07_047_9904EN 4

S

2 3 41

1 Transfer tube2 Thrust ring3 Wear ring4 Spectacle wear plate

" Check the gap �S" between the transfer tube and wear ring.

NoteThe gap between the transfer tube and the wear ring must be 1.5 to2�mm.

Check sealing gap


6��46 AP07_068_1007EN

After each pumping operation, you must clean the transfer tubebearing thoroughly to prevent any concrete encrustation in thetransfer tube bearing.

AP07_068_1007EN 1

1 3

45

2

No. 0 Designation

1 S transfer tube2 Areas that must be cleaned3 Pressure connection4 Lubrication points5 Transfer tube bearing

" Carefully spray out the areas to be cleaned�(2) on the pressureconnection�(3) and on the transfer tube bearing�(5).

" Immediately after cleaning, use the lubrication pointprovided�(4) to grease the transfer tube bearing�(5).� Grease is visible between the S transfer tube�(1) and

transfer tube bearing�(5).

Cleaning the gapbetween the transfertube bearing and theS transfer tube


6��47AP07_048_1007EN

Once the delivery line, hopper, delivery cylinders and S transfertube�have been washed out, you must thoroughly rinse down allother parts of the machine that have come into contact with con�crete. Concrete that is not washed off immediately can attack thepaint, especially if aggressive concrete additives have been used.

CautionThe delivery line, water box, water tank and water pump must bedrained fully if there is a risk of freezing. The water box must also bedrained at normal temperatures during longer breaks in pumping,e.g. overnight and at weekends.Leave the water outlet open afterwards.

Danger of explosionAtomized preserving agents are highly explosive. Keep away from allsources of ignition whilst spraying.

Danger of poisoningCleaning agents, solvents or preserving agents sprayed in air canenter the lungs and trigger serious damage to health. You should,therefore, always wear respiratory protection during this work.

6.9.4 Post-cleaningprocedure


6��48 AP07_048_1007EN

" Clean all seals and the seal seats.

" Grease the seals before replacing them.

" Clean the remaining parts of the machine by rinsing downwith�water.

" At the lubrication point provided, grease all of the bearingpoints in the hopper area immediately after washing it out.� Grease is visible on the lubrication point.

" Grease all of the exposed piston rods.

" Grease the interior surfaces of the delivery cylinder.

" Then spray the metal components with an anticorrosion agentor release agent.


6��49AP07_078_1501EN

When placing stationary concrete pumps in storage for more thanfour weeks, you must carry out the following measures to preservetheir value. Carry out these measures at least every three�months. Ifrequired due to the climatic conditions to which the stored machineis exposed, you must carry out these measures at shorter intervals.

Checklist for value preservation measures for stationary concrete pumps placed into storage

Assembly Action

DocumentationDocument the date that the machine is placed in storage and thevalue preservation measures that are carried out.

Protect the untreated surfaces (control blocks, pins, spring pins,etc.) with a suitable preserving agent.

General Grease the untreated surfaces of mechanical parts (rollers,chains, etc.) with Vaseline.

Rectify any corrosion damage.

Electrical system

Disconnect the battery.See the instructions on how to switch off DEUTZ engines with anEMR4 electronic engine governor in the section "Switching off themachine".

Electrical systemCheck the battery charge state and charge the battery if necess�ary.

Connect the central control unit (CCU) to a supply voltage at six−monthly intervals.

Empty the water tank and the water lines. Leave the drainageopenings open.

Water Drain the water box. Leave the drainage openings open. Closethe water box cover.

Drain the high�pressure water pump.

Concrete pumpGrease all exposed piston rods with Vaseline.

Concrete pumpGrease the interior surfaces of the delivery cylinder with Vaseline.

6.10 Measures for preserv-ing the value of sta-tionary concretepumps placed in stor-age


6��50 AP07_078_1501EN

Assembly Action

Open and lock the hopper flap.

Hopper Close the spray guard.pp

Spray the hopper area with barrier agent.

Cover any exhaust pipes that exit upwards.

Engine Close the fuel tank and the supply line to the engine.g

Protect the electronics against moisture/corrosion.

Exhaust After Treatmentsystem (EAT system)

Fill the DEF container completely.Maximum storage duration at −40 °C to 25 °C is four months.

CautionThe instructions in this warning notice apply to DEUTZ motors withan electronic engine governor (EMR4).When you switch off the ignition, the control unit of the electronic en�gine governor (EMR4) is still supplied with power for approx.two�minutes. During this run−down time, required data is saved in thecontrol unit and the DEF lines are emptied (risk of freezing).

You must only disconnect or switch off the battery once the controlunit has completed its run−down time of approx. two�minutes. Inter�rupting this run�down time will cause a fault in the control unit.

Putzmeister will not accept warranty claims for engine damage andoperating errors that result from a failure to switch off the engine ac�cording to the instructions.

NoteRefer to the engine manufacturer’s documentation for details aboutpreserving the engine and the exhaust after treatment system.

Glossary

7��IBP14_001_0501EN

7 Glossary

This chapter illustrates the control system symbols (icons for con�crete pumps) and explains the abbreviations and technical termsthat are used in Putzmeister Operating Instructions.

Glossary

7��II BP14_001_0501EN

Glossary

G��1BP14_003_0501EN

G–1 Symbols for concrete pumps in accordance with German Mechanical EngineeringAssociation Standard (VDMA 24119)

G–1.1 General (for key, see page G — 7)

3701

3702

3703

3704

3705

3706

3707

3708

3709

3710

3711

3712

3713

3714

3715

3716

3717

3718

3719

3720

3721

3722

3723

3724

3725

4001

4002

4003

4004

5001

5002

5003

5004

5005

5006

5007

5008

6001

6002

6003

6004

6005

6006

6007

6008

6009

6010

6011

6012

6013

6014

6015

6016

PM6017

PM6018

PM6019

7001

7002

7003

7004

7005

7006

7007

7008

7009

7010

7011

7012

8001

8002

8003

8004

Glossary

G��2 BP14_003_0501EN

8005

8006

8007

8008

8009

9001

9002

9003

10001

10002

10003

10004

10005

10006

10007

10008

10009

10010

10011

10012

10013

10014

10015

10016

10017

10018

10019

10020

10021

10022

10023

10024

10025

11001

11002

11003

12001

12002

12003

12004

12005

12006

12007

12008

12009

12010

12011

12012

12013

12014

12015

12016

12017

12018

12019

12020

12021

12022

12023

12024

12025

12026

12027

12028

12029

12030

12031

12032

12033

12034

12035

12036

Glossary

G��3BP14_003_0501EN

12037

12038

12039

12040

12041

12042

12043

12044

12045

12046

12047

12048

12049

12050

12051

12052

12053

12054

12055

12056

12057

13001

13002

13003

13004

PM13005

PM13006

PM13007

14001

14002

14003

15001

15002

15003

G–1.2 Support (for key, see page G — 10)

2601

2602

2603

2604

2605

2606

2607

2608

2609

2610

2611

2612

2613

2614

2615

2616

2617

Glossary

G��4 BP14_003_0501EN

G–1.3 Boom, 2–arm (for key, see page G — 10)

1201

1202

1203

1204

1205

1206

1207

1208

1209

1210

1211


1301

1302

1303

1304

1305

1306

1307

1308

1309

1310

1311

1312

1313

1314

1315

1316


1401

1402

1403

1404

1405

1406

1407

1408

1409

1410

1411

1412

1413

1414

1415

1416

1417

1418

1419

1420

1421

1422

1423

1424

1425

1426

1427

Glossary

G��5BP14_003_0501EN


1501

1502

1503

1504

1505

1506

1507

1508

1509

1510

1511

1512

1513

1514

1515

1516

1517

1518

1519

1520

1521

1522

1523

1524

1525

1526

1527

1528

1529

1530


PM1601

PM1602

PM1603

PM1604

PM1605

PM1606

PM1607

PM1608

PM1609

PM1610

PM1611

PM1612

PM1613

PM1614

PM1615

PM1616

Glossary

G��6 BP14_003_0501EN

G–1.8 Ergonic Boom Control, 3–arm (for key, see page G — 13)

PM1301

PM1302

PM1303

PM1304

PM1305

PM1306

PM1307

PM1308

PM1309


PM1401

PM1402

PM1402A

PM1403

PM1403A

PM1404

PM1405

PM1406

PM1406A

PM1407

PM1407A

PM1408

PM1409

PM1410

PM1411

PM1412

PM1413

PM1414


PM1501

PM1502

PM1502A

PM1503

PM1503A

PM1504

PM1505

PM1506

PM1506A

PM1507

PM1507A

PM1508

PM1509

PM1510

PM1511

PM1512

PM1513

PM1514


PM1601

PM1602

PM1603

PM1604

PM1605

PM1606

PM1607

PM1608

PM1609

PM1610

PM1611

Glossary

G��7BP14_004_0905EN

G–2 Key to the symbols for concrete pumps

G–2.1 General

3701 Increase/reduce output using rotary�controller

3702 Increase/reduce output using toggle�switch

3703 Increase output

3704 Reduce output

3705 Reverse pumping

3706 Pumping On

3707 Pumping Off

3708 Pumping On�−�Off

3709 Pumping stand�by

3710 Pumping in general

3711 Rotor pump in general

3712 Pump flow meter

3713 Full output

3714 Half output

3715 High pressure pump

3716 Pump control system

3717 Change−over

3718 Stroke pulse change−over

3719 Stroke correction

3720 Change−over delay

3721 Screw conveyor�1 anticlockwise rotation

3722 Screw conveyor�1 clockwise rotation

3723 Screw conveyor�2 anticlockwise rotation

3724 Screw conveyor�2 clockwise rotation

3725 Screw conveyor

4001 Centralised grease lubrication, manual

4002 Centralised grease lubrication, automatic

4003 Centralised oil lubrication, manual

4004 Centralised oil lubrication, automatic

5001 Agitator, hopper

5002 Agitator clockwise rotation

5003 Agitator anticlockwise rotation

5004 Hopper empty

5005 Hopper full

5006 Agitator cut−out

5007 Hopper level control

5008 High−pressure agitator

6001 Hydraulic oil excess temperature

6002 Radiator

6003 Radiator�1

6004 Radiator�2

6005 Fill accumulator

6006 Dump accumulator pressure

6007 Hydraulic cylinder blockage

6008 High−pressure hydraulic system

6009 Insufficient hydraulic fluid

6010 Hydraulic fluid

6011 Air

6012 High pressure

6013 Accumulator pressure

6014 Filter element

6015 Rod side

6016 Piston side

PM6017 Hydraulic fluid filter water level STOP

PM6018 Hydraulic fluid filter water level warning

PM6019 Hydraulic fluid filter contamination warning

7001 Working light

7002 Lighting

Glossary

G��8 BP14_004_0905EN

7003 Control cabinet lighting

7004 Toolbox lighting

7005 Rear light

7006 Spirit level lighting

7007 Flashing beacon

7008 Acknowledge flashing beacon

7009 Brake light

7010 Side marker lamps container

7011 Lighting mast

7012 Diagnostics lamp

8001 Machine diagnostics connector

8002 Read−out data

8003 Read−in data

8004 Read−in minimum value

8005 Reset memory contents (save)

8006 Cancel memory contents (clear)

8007 Start

8008 Read−in maximum value

8009 Menu

9001 Control cabinet

9002 Diagnostics socket

9003 Teleservice

10001 Diesel engine On

10002 Diesel engine Off

10003 Engine oil excess temperature

10004 Cooling water excess temperature

10005 Acknowledge cooling water excess temperature

10006 Engine oil pressure

10007 V−belt failure

10008 Increase speed, reduce speed

10009 Speed

10010 Speed sensor

10011 Increase speed

10012 Reduce speed

10013 Engine air filter

10014 Electric motor in general

10015 Silent

10016 Reduced fuel consumption

10017 Tank monitoring

10018 Coolant level

10019 Diesel engine control

10020 Starter

10021 Manual throttle lever

10022 Start−up relief (soft start)

10023 Diesel supply On

10024 Fuel

10025 Fuel filter draining

11001 Radio remote control

11002 Remote control in general

11003 Plug in remote control

12001 Horn

12002 Fault in general

12003 Acknowledge

12004 Battery

12005 Battery charging device

12006 EMERGENCY STOP activated

12007 Acknowledge EMERGENCY STOP

12008 Stop

12009 Test operation

12010 Vibrator On

12011 Vibrator Off

12012 Vibrator

Glossary

G��9BP14_004_0905EN

12013 Potentiometer

12014 Off�−�On

12015 On

12016 Off

12017 Fast (e.g.�acceleration)

12018 Normal (e.g.�acceleration)

12019 Compressor

12020 Compressor On�−�Off

12021 Motor vehicle fuse

12022 Cable drum

12023 Operating hours meter

12024 Operating position

12025 Electrical power

12026 Automatic/manual

12027 Automatic operation

12028 Close shut−off device

12029 Open shut−off device

12030 Water tank heating

12031 Cleaning

12032 Levelling control in general

12033 Excess pressure

12034 Fuse test

12035 Timer relay

12036 Right side

12037 Left side

12038 Concrete brake

12039 Buzzer

12040 Container

12041 Position at the machine

12042 Lock

12043 2nd�level

12044 Circuit�1

12045 Circuit�2

12046 Circuits�1+2

12047 High−pressure limit

12048 Flap/closure closed

12049 Flap/closure open

12050 Generator

12051 Boom on cradle

12052 Manual operation

12053 Electrical levelling

12054 See Operating Instructions

12055 Wear measurement

12056 Water

12057 Overhead roll−and−fold boom

13001 Power take−off

13002 Truck in general

13003 Plan view

13004 Brake in general

PM13005 Driving

PM13006 Lifting axle raised

PM13007 Lifting axle not raised

14001 Mixer in general

14002 Drain mixer

14003 Activate mixer

15001 Water glass dosing pump

15002 Flushing water pump

15003 High−pressure water pump

Glossary

G��10 BP14_004_0905EN

G–2.2 Support

2601 Support leg/foot retract/extend

2602 Extend support leg

2603 Retract support leg

2604 Lower support foot

2605 Raise support foot

2606 Swing out right support leg

2607 Swing in right support leg

2608 Swing out left support leg

2609 Swing in left support leg

2610 Support leg working light

2611 Support leg retract/extend

2612 Support foot retract/extend

2613 Side marker lamps support leg

2614 Working range on the right

2615 Working range on the left

2616 Enable stability monitoring

2617 Stability monitoring

G–2.3 Boom, 2–arm

1201 Boom in general

1202 Arm 1 up

1203 Arm 1 down

1204 Arm 2 up

1205 Arm 2 down

1206 Boom activated

1207 Slew boom to the left

1208 Slew boom to the right

1209 Move arms

1210 Move arms switched off

1211 Slewing gear activated



1302 Arm 1 up

1303 Arm 1 down

1304 Arm 2 up

1305 Arm 2 down

1306 Arm 3 up

1307 Arm 3 down

1308 Boom activated



1311 Move arms



1314 Slew boom to the right switched off

1315 Slew boom to the left switched off

1316 Arm�1 down switched off

Glossary

G��11BP14_004_0905EN



1402 Arm 1 up

1403 Arm 1 down

1404 Arm 2 up

1405 Arm 2 down

1406 Arm 3 up

1407 Arm 3 down

1408 Arm 4 up

1409 Arm 4 down

1410 Boom activated



1413 Move arms



1416 Arms up switched off




1420 Arms up switched on

1421 Tilt switch, arm�1 circuit�1




1425 Pressure switch, arm�1 circuit�1


1427 Unfolding position

Glossary

G��12 BP14_004_0905EN



1502 Arm 1 up

1503 Arm 1 down

1504 Arm 2 up

1505 Arm 2 down

1506 Arm 3 up

1507 Arm 3 down

1508 Arm 4 up

1509 Arm 4 down

1510 Arm 5 up

1511 Arm 5 down

1512 Boom activated




1516 Move arms





1521 Arms up switched on







1528 Unfolding position

1529 Arm�5 switched on

1530 Arm�5 switched off


PM1601 Boom in general

PM1602 Arm 1 up

PM1603 Arm 1 down

PM1604 Arm 2 up

PM1605 Arm 2 down

PM1606 Arm 3 up

PM1607 Arm 3 down

PM1608 Arm 4 up

PM1609 Arm 4 down

PM1610 Arm 5 up

PM1611 Arm 5 down

PM1612 Arm 6 up

PM1613 Arm 6 down

PM1614 Boom activated

PM1615 Slew boom to the left

PM1616 Slew boom to the right

Glossary

G��13BP14_004_0905EN

G–2.8 Ergonic Boom Control, 3–arm

PM1301 Move end hose

PM1302 End hose forwards

PM1303 End hose back

PM1304 End hose up

PM1305 End hose down

PM1306 Unfold the placing boom

PM1307 Fold the placing boom

PM1608 End hose to the left

PM1309 End hose to the right




PM1402A End hose forwards (USA)


PM1403A End hose back (USA)

PM1404 End hose up



PM1406A Unfold the placing boom (USA)


PM1407A Fold the placing boom (USA)



PM1410 Upper limit

PM1411 Lower limit

PM1412 Preferred position for arm 1


PM1414 Preferred position arm�1 + arm�4

Glossary

G��14 BP14_004_0905EN




PM1502A End hose forwards (USA)


PM1503A End hose back (USA)

PM1504 End hose up



PM1506A Unfold the placing boom (USA)


PM1507A Fold the placing boom (USA)



PM1510 Upper limit

PM1511 Lower limit



PM1514 Preferred position arm�1 + arm�5





PM1604 End hose up








Glossary

G��15BP14_002_0501EN

G–3 Abbreviations and technical terms

A

ADR Arbeitsdrehzahlregelung → Speed of rotation regulation

Agitator safety cutout The agitator safety cutout automatically cuts power to the agitatorand the concrete pump when the grille is opened.

APP → Automatic Piston Pull

Arc configuration Variant of boom movement in Ergonic Boom Control mode onmachines with a Z fold system: the position of the arm assemblyresembles an arc.

Automatic Piston Pull A ball cock is fitted in the drive cylinder. When the ball cock isclosed, you can pull the delivery piston out of the delivery cylinderto replace it.

B

Blockage Blockage in the delivery line: the concrete behind the blockagecannot continue to flow. The blockage may occur due to wedgingcaused by coarse particles, etc.

C

Change−over Reversal of direction of the delivery piston in the middle of a strokemovement: The → transfer tube switches over. The concrete is stillpumped without interruption.

Change−over delay throttle The change−over delay throttle is a hydraulic component whichdelays the change−over of the → transfer tube.

Check book The check book is part of the documentation accompanying themachine: checklist with confirmation of the legally required checksfor concrete pumps and placing booms

Corner bearing load The corner bearing load is the force transferred to the groundthrough each support foot.

Glossary

G��16 BP14_002_0501EN

D

dB Decibels: unit of measurement for the → sound power level

dB (A) Decibels (A): unit of measurement for the → sound pressure level

E

EBC → Ergonic Boom Control

EDC → Electronic Diesel Control

EGD → Ergonic Graphic Display

EGD−RC → Ergonic Graphic Display � Remote Control

Electronic Diesel Control Automatic vehicle−specific control of fuel consumption

EOC → Ergonic Output Control

EPS → Ergonic Pump System

Ergonicr Registered brand name for all Putzmeister components whichcontrol concrete pumps and placing booms.

Ergonic Boom Control Microprocessor supported system for controlling and regulatingthe placing boom. Among other functions, EBC allows you to movethe placing boom using just one joystick.

Ergonic Graphic Display Graphic display in the control cabinet door. The operating state ofthe machine is shown in the display. You may also be able to setfunctions here, depending on the equipment on your machine.

Ergonic Graphic Display �Remote Control

Graphic display in the remote control. The operating state of themachine is shown in the display. You may also be able to setfunctions here, depending on the equipment on your machine.

Ergonic Output Control Microprocessor supported system for economic operation ofthe�concrete pump. The minimum engine speed required forthe�delivery rate selected by the operator is automatically set.

Ergonic Pump System Microprocessor supported system for controlling and regulatingthe concrete pump. Among other functions, EPS allows you torestrict the concrete pressure and delivery rate.

Glossary

G��17BP14_002_0501EN

F

FFH → Free−Flow Hydraulics

Free−Flow Hydraulics Free−Flow Hydraulics is a type of drive for the concrete pumpwhich switches the fluid flow from the main pump directly to thedrive cylinders, i.e. there is free fluid flow without interposedvalves.�

Fully hydraulic control Fully hydraulic control is a type of control of the concrete pumpwhich switches the fluid flow from the main pump to the drivecylinder using valves (closed hydraulic circuit).

Functional fluids Hydraulic fluid, fuel, brake fluid, battery acid etc.

G

Grille The grille is the protective cover for the hopper and has twofunctions:− Allowing only particles up to a certain size to pass− Protecting persons against reaching into the hopper

K

KEP Kolben−Endlagen−Positionierung → Piston end−of−travelpositioning

L

Lela → Levelled last arm

Level control Level control controls the amount of concrete in the hopper duringpumping operations using a fill−level sensor.

Levelled last arm Last arm of the placing boom in a horizontal position

Glossary

G��18 BP14_002_0501EN

M

Machine card The machine card is part of the documentation accompanyingthe�machine:− List of machine components− Circuit diagram information

Maintenance card A maintenance card describes measures and their sequence formaintaining the machine and for replacing parts and wear parts.

Monoblock The monoblock is a hydraulic safety valve on the boom hydrauliccylinders.

N

NA / NMV NA and NMV are types of power take−off:− The NA power take−off is a transmission−dependent PTO.− The NMV power take−off is independent of the clutch.

O

One−Side−Support One−Side−Support is a type of support for supporting the machinein narrow spaces.

Operating equipment Battery, filters

OSS → One−Side−Support

P

PEDOC → Putzmeister Electronic Documentation

Piston end−of−travel positioning A ball valve is fitted in the drive cylinder. When the ball valve isclosed, you can lock the drive cylinder in its end−of−travel positionto replace it.

Piston side

Proportional control Infinitely variable controller for setting the boom speed

Putzmeister ElectronicDocumentation

Documentation accompanying the machine on CD−ROM

Glossary

G��19BP14_002_0501EN

Q

Quick disconnect point Arm 1 of the arm assembly can be disconnected at the quickdisconnect point.

R

Reversal The concrete is sucked back from the delivery line into the hopper.

Rod side

Roll−and−fold system Type of folding of the arm assembly: the arm is rolled when foldedin and out.

Roll configuration Position of the M 31 arm assembly in Ergonic Boom Controloperation when the end hose is moved within the stored limits.

Rotor pump The rotor pump comprises− a rotor housing− a rotor (rotating about its central axis)− two pressure rollers (running freely)− a pump tubeThe pump tube is pressed together as the pressure rollers rollover�it. This pushes the concrete in the pump tube ahead ofthe�pressure roller towards the rotor housing outlet and into thedelivery line.

RSA Rührwerksicherheitsabschaltung → Agitator safety cutout

Glossary

G��20 BP14_002_0501EN

S

Service operation The �Pumping operations − Service operations" toggle switchon�the control cabinet can be used to switch over between theconcrete pump and the compressor. You can switch on thecompressor, rather than the pump, at the radio remote control ifyou set the switch to �Compressor".

Snaplock The snaplock is a mechanical safety device to protect againstunintentional extension and retraction of the support legs.

Sound power level The sound power level is a relative measurement used in acous�tics to indicate the noise emissions from a noise source�[dB].

Sound pressure level The sound pressure level is a logarithmic measurement for therelative loudness of the sound [dB(A)].

Speed of rotation regulation The ADR function regulates the mixer drum speed while the truckis being driven.

Squeeze valve The squeeze valve is a component on the end hose which closesthe delivery line when the pump is stopped.

Stroke correction The stroke is corrected automatically by the addition or removal ofhydraulic fluid through bores in the cylinder. This means that thedelivery piston can achieve its maximum stroke length. Withoutstroke correction, the delivery piston would not always reach itsend position.

Support foot The support foot is a component on the end of the support leg.

Support leg The support leg is a telescopic and/or slewable component forsupporting the machine.

Support foot plate The support foot plate is a component on the underside of thesupport foot.

Glossary

G��21BP14_002_0501EN

T

Teach−in Specialist word for storing in memory

Test reading The test reading is part of the documentation accompanying themachine: list of machine setting values

to trigger The magnetic switches are triggered, i.e.� when an object isbrought near, they switch without any contact being made.

Transfer tube The transfer tube is a component which is swung between the twodelivery cylinders in the hopper. It is the connection between thedelivery cylinder and the delivery line.

U

UVD Umsteuer−Verzögerungsdrossel → Change−over delay throttle

V

VHS Vollhydraulische Steuerung → Fully hydraulic control

Z

Z fold system Type of folding of the arm assembly: the arm assembly resemblesthe letter Z when folded in and out.

Z configuration Variant of boom movement in Ergonic Boom Control mode onmachines with a Z fold system: the position of the arm assemblyresembles the letter Z.

Glossary

G��22 BP14_002_0501EN

Index�of�key�words

8 — I

8 Index of key words

In this section you will find the most important key words with thenumber of the page on which you will find the key word as a headingin the left margin. This Index of key words is listed alphabetically bythe main concepts. These are subdivided into associated sub−con�cepts, marked with a dash.


8 — II


i

AAbbreviations, G��15

Accessories and attachments, 2��15

After Sales Service personnel, Defini-tion of terms, 2��3

Agitator, 4��18� Emergency operation, 3��89� Function description, 3��14

Agitator hopper, Filling, 6��11

Agitator safety cutout, 3��78� Acknowledge, 4��14� Inspection, 4��12� Unexpected restart, 4��14

Approach route� For the machine, 5��11� For truck mixers, 5��11� Minimum clearance from pits, 5��13

Arm assembly, Definition of terms,2��1

Assembly, Stationary delivery line,5��18

Auxiliary personnel, Definition ofterms, 2��2

BBase structure, Definition of terms,2��1

Blockages, 2��42, 6��16

Breaks in pumping, 6��17

CCable remote control, 3��74

Catch basket, 6��29

Centralized lubrication system, Des-cription of the functions, 3��18

Change-over, Description of the func-tions, 3��13

Changes to the machine, 2��15

Chassis� Crawler track, 5��7� Description of the functions, 3��10� F 8, 5��4� F�25, 5��4� F�80, 5��5� Static base structure, 3��11, 5��7� Transport, 5��4

Checks� Function checks, 4��9� Visual checks, 4��1

Cleaning, 2��48, 6��25� Catch basket, 6��29� Cleaning agents, 2��49� Compressed air, 2��50� Compressed air cleaning, 6��27� Concrete leavings, 6��26� Delivery line, 6��34� High−pressure water cleaning, 6��38� Hopper, delivery cylinder and S trans�fer tube, 6��41

� Mark the water hose, 6��33� Post−cleaning procedure, 2��51, 6��47� Preparations, 6��28� Sponge ball, 6��28� Suction cleaning, 6��36� T−delivery pipe with wash−out port,6��31

� Wash−out adaptors, 6��30� With auxiliary pump, 6��39

Cleaning agents, 2��49

Clearances� From high�voltage lines, 2��22� To delivery lines, 2��43

Cold weather, 2��40

Components� Other, 3��91� Overview, 3��1

Compressed air cleaning, 2��50, 6��27

Concrete leavings, 6��26

Concrete properties, 6��10

Concrete pump, Definition of terms,2��1

Condensate water, 4��3

Control cabinet with SPC display unit,3��21, 3��27

Control devices� Agitator valve, 3��89� Drive cylinder emergency operation,3��88

� Electrical, 3��20� Emergency operation � transfer tube,3��88

� Hydraulic, 3��85� Magnetic switches distributor casing,3��80

� Pump control system, 3��88

Cooling, 6��19

Copyright, 1��2

Corner bearing load, 2��30

Crawler track, 3��11, 5��7

DDanger zone, 2��4, 2��7� Delivery line systems, 2��8� End hose, 2��8, 2��38� Hopper, 2��8� Machine, 2��8� Placing boom, 2��7� Stationary delivery line, 5��19� Support legs and support feet, 2��7

DEF container, Filling, 6��6

Definition of terms� After Sales Service personnel, 2��3� Arm assembly, 2��1� Auxiliary personnel, 2��2� Base structure, 2��1� Concrete pump, 2��1� Danger zone, 2��4, 2��7� Delivery line systems, 2��2� End hose, 2��2� Hoseman, 2��2� Machine, 2��1� Machine operator, 2��2� Maintenance, 2��3� Manufacturer, 2��2� Operator, 2��2� Place of work, 2��4, 2��6� Placing boom, 2��1� Qualified personnel, 2��3� Signaller, 2��2� Subject expert, 2��3� Truck mixer, 2��2� Truck mixer driver, 2��3� Working area, 2��4, 2��6

Delivery line, Cleaning, 6��34

Delivery line systems, 2��41� Clearance to delivery lines, 2��43� Continuation delivery lines, 2��44� Danger zone, 2��8� Definition of terms, 2��2� Fastening delivery lines, 2��43� Leak tightness and blockages, 2��42� Opening the delivery line, 2��43� Securing delivery lines, 2��41� Shutting−off, diverting, cleaning, 2��44� Suitable delivery line, 2��41


ii

Description of the functions, 3��10� Centralized lubrication system, 3��18� Change�over, 3��13� Chassis, 3��10� Pump, 3��12� Pumping, 3��13� Reverse pumping, 3��13� S transfer tube, 3��13� Support legs, 3��11� Water box, 3��13

Designated use, 2��9� Inspection intervals, 2��11� Retesting (safety inspection), 2��10

Diesel engine, 6��18� Switching on, 4��7

Diesel Oxidisation Catalyst/DieselParticle Filter (DOC/DPF) module,3��99

Discharge voltage pattern, 2��22

Downpipe, 5��25

DPF regeneration strategy, 3��101

Drills, Connecting, 2��39

Driving, 2��33� Before moving off, 5��6� During the journey, 5��7� Hand signals, 5��5, 5��8

EEarthing, 2��25

Earthing on construction sites withspecial equipment, 2��25

EGD symbols� Agitator safety cutout, 3��40� Fill level of the DEF container (green) ,3��43

� Fill level of the DEF container (orange),3��43

� Fill level of the DEF container (red),3��43

� Fill level of the DEF container (yellow),3��43

� Warning symbol for DEF quality, 3��45� Warning symbol for DEF quality andexhaust gas treatment (green), 3��44

� Warning symbol for DEF quality andexhaust gas treatment (grey), 3��44

� Warning symbol for DEF quality andexhaust gas treatment (orange), 3��44

� Warning symbol for DEF quality andexhaust gas treatment (red), 3��44

� Warning symbol for DEF quality andexhaust gas treatment (yellow), 3��44

� Warning symbol for DPF regeneration(green), 3��47

� Warning symbol for DPF regeneration(grey), 3��47

� Warning symbol for DPF soot filter(grey), 3��48

� Warning symbol for DPF soot filter (yel�low), 3��48

� Warning symbol for DPF soot filterchange (red), 3��48

� Warning symbol for engine oil changerequired (yellow), 3��48

� Warning symbol: DPF regeneration(orange), 3��47

� Warning symbol: DPF regeneration(red), 3��47

� Warning symbol: DPF regeneration(yellow), 3��47

� Warning symbol: DPF regenerationcomplete (green), 3��47

� Warning symbol: DPF regenerationrunning (yellow), 3��47

� Warning triangle, orange, 3��37� Warning triangle, red, 3��37� Warning triangle, yellow, 3��37

Electromagnetic compatibility, 3��6

Electrostatic charging, 2��25

EMC, 3��6

Emergency operation� Agitator, 3��89� Drive cylinder, 3��88� Transfer tube, 3��88

EMERGENCY STOP button, 2��37,3��74, 3��76, 4��11

EMERGENCY STOP function, 4��11

End hose, 2��38� Danger zone, 2��8, 2��38� Definition of terms, 2��2� Ergonomically, 2��39� Extending, 2��13� Impermissible end hose, 2��13

Engine, Possible faults, 4��24

EOC, Ergonic Output Control, 3��66

Ergonic Graphic Display, Menu struc-ture, 3��29

Ergonic Output Control, 3��66

Exhaust after treatment system, 3��95,6��20

Extensions, End hose and placingboom, 2��13

FF 8 chassis, 5��4

F 25 chassis, 5��4

F 80 chassis, 5��5

Face mask, 2��20

Fastening, Stationary delivery line,5��22

Filling with fuel, Machine, 6��5

Filter� Pressure filter, 4��17� Suction filter, 4��16

Filter condition, 4��16� Pressure filter, 3��90� Suction filter, 3��90

Flash over, 2��24

Flushing water pump, 3��92, 4��19,5��29

Function checks, 4��9� Agitator, 4��18� Agitator safety cutout, 4��12� EMERGENCY STOP function, 4��11� Filter condition, 4��16� Flushing water pump, 4��19� Magnetic switches, 4��9� Pump, 4��9� Vibrator, 4��20

Function description, Agitator, 3��14

Fuse box, 3��69

GGeneral conditions� For using a concrete pump, 3��15� Height of job, 3��16� Operating temperature, 3��17� Service life, 3��15� Site of use, 3��16

HHand signals� Driving, 5��5, 5��8� Pumping operations, 6��3

Hearing protectors, 2��19

Height of job, 3��16


iii

High–pressure water cleaning, 6��38

High–voltage lines, 2��22� Clearances, 2��22� High�voltage warning device, 2��24� Procedure in the event of a flash over,2��24

High-pressure delivery, 2��15

High-voltage warning device, 2��24

Hopper� Cleaning, 6��41� Danger zone, 2��8

Hoseman, Definition of terms, 2��2

Hydraulic fluid radiator, 4��3

Hydraulic system, 4��1

IIcons, 1��3

Impermissible end hose, 2��13

Impermissible working area, 2��6,2��14

Improper use, 2��12� Accessories and attachments, 2��15� Changes to the machine, 2��15� Climbing the placing boom, 2��14� Exclusion of liability, 2��15� Extending the reach, 2��12� Extensions, 2��13� High�pressure delivery, 2��15� Impermissible end hose, 2��13� Impermissible working area, 2��14� Lifting loads, 2��12� Removing obstacles, 2��12� Transporting goods, 2��12

Inputs and outputs menu, Symbols inthe menu bar, 3��64

Inspection intervals, 2��11

Instructions for laying the line, Statio-nary delivery line, 5��20

LLiability, Exclusion, 2��15

Lifting eyes, 5��2, 5��3

Lifting loads, 2��12, 2��27

Lifting points, 2��35

Loading, 2��27, 2��35, 5��1� Lifting points, 2��35

Locking, 3��26

Lubrication menu, Symbols in themenu bar, 3��61

Lubrication points, 4��3

MMachine� Danger zone, 2��8� Definition of terms, 2��1� Moving machine components, 2��46� Observing, 2��47� Setting up, 5��14� Switching off, 4��21� Switching on, 4��7

Machine operator� Definition of terms, 2��2� Responsibility of the machine operator,2��16

Magnetic switches, 3��80� Connector with LEDs, 3��83� Function check, 4��9

Magnetic switches distributor casing,3��80

Maintenance, Definition of terms, 2��3

Manufacturer, Definition of terms, 2��2

Minimum clearance from pits, 5��13

Mobile machines, 2��28� Set�up site, 2��28� Supporting ground, 2��29

Monitoring, 6��14

OOperating Instructions, 2��17

Operating procedures, 2��17, 2��18

Operating temperature, 3��17

Operator, Definition of terms, 2��2

Output controller, 3��86

Overheating, 6��18

Overview, Components, 3��1

PParts in contact with concrete, 4��5

Personal protective equipment, 2��19

Personnel, 2��15� Qualifications, 2��16

� Requirements, 2��16� Responsibility of the machine operator,2��16

Place of work, 2��4, 2��6� Place of work � hoseman, 2��6� Place of work � machine operator, 2��6� Place of work � truck mixer driver, 2��6� Pumping operations, 2��45

Placing boom, 2��36, 2��40� Climbing, 2��14� Danger zone, 2��7� Definition of terms, 2��1� Extending, 2��13� Procedure in storms, 2��40� Unfolding, 2��36� Wind speeds, 2��40

Preparations for cleaning, 6��28

Preserving the value of stationaryconcrete pumps placed in storage,6��49

Pressure filter, 3��90

Pressure gauge, 3��90

Protective equipment, 2��19� Face mask and respiratory protector,2��20

� Hearing protectors, 2��19� Protective gloves, 2��20� Protective goggles, 2��20� Safety footwear, 2��19� Safety harness, 2��20� Safety helmet, 2��19

Protective gloves, 2��20

Protective goggles, 2��20

Pump, Description of the functions,3��12

Pump control system, 3��88

Pump functions� Stroke length, 4��10� Stroke time, 4��10

Pumping operations, 2��45� Blockages, 6��16� Breaks in pumping, 6��17� Concrete properties, 6��10� Cooling, 6��19� Diesel engine, 6��18� Exhaust after treatment system, 6��20� Filling the agitator hopper, 6��11� Hand signals, 6��3� Monitoring, 6��14� Overheating, 6��18


iv

� Preconditions, 6��1� Pumping, 6��13� Safety, 2��45� Saturated mix, 6��10� Starting pumping, 6��12

QQualifications, 2��16

Qualified personnel, Definition ofterms, 2��3

RRating plate, Machine, 3��7

Reaches, Extending, 2��12

Ready for operation� Checking, 2��21� Rendering the machine ready, 2��21

Regulations, 2��17, 2��18

Remote control, 2��45, 6��2� Cable remote control, 3��74

Removing obstacles, 2��12

Respiratory protection, 2��20

Responsibility of the machine opera-tor, 2��16

Restrictions, Cold weather, 2��40

Retesting (safety inspection), 2��10

Reverse pumping, Description of thefunctions, 3��13

Riser, 5��25

Rod side – piston side feed, 5��27

SS transfer tube, Description of the

functions, 3��13

Safety equipment, 3��3

Safety footwear, 2��19

Safety harness, 2��20

Safety helmet, 2��19

Selective Catalytic Reduction (SCR),3��97

Service life, 3��15

Set-up site, 2��26, 2��28, 5��10� Accessibility, 5��11� Approach route, 5��11� Approach route for truck mixers, 5��11

� High−voltage lines, 2��22� Minimum clearance from pits, 5��13� Space for truck mixers, 5��11� Supporting ground, 5��12� Supports, 2��31

Setting up, Machine, 5��14

Shutting down the motor, 4��21

Signaller, Definition of terms, 2��2

Site of use, 3��16

SK delivery line system, 5��26

Sound power level, 3��8

Sound pressure level, 3��8

Space requirement, For truck mixers,5��11

SPC, SPC display, 3��27

SPC display� All symbols in the menu bar, 3��32,3��51

� All symbols in the menu bar in the in�puts and outputs menu, 3��64

� All symbols in the menu bar in the lu�brication menu, 3��61

� Battery charging control, 3��39� CAN bus communication CAN1, 3��38� CAN bus communication CAN2, 3��39� Coolant level, 3��38� DEF crystallisation, 3��46� DEF hardware, 3��45� DEF manipulation, 3��45� DEF quality, 3��45� Delivery rate, 3��41� EMERGENCY STOP, 3��40� Engine oil pressure, 3��38� Engine oil temperature, 3��38� EOC, 3��41� Ergonic Output Control, 3��66� Expanded HOME, 3��49� Fault memory, 3��55� Forward pumping, 3��40� Fuel filter, 3��38� Function buttons in the expandedHOME menu, 3��49

� Function buttons in the HOME menu,3��31

� Function buttons in the inputs and out�puts menu, 3��63

� Function buttons in the lubricationmenu, 3��60

� Function buttons in the user settingsmenu, 3��57

� HOME, 3��31

� Hydraulic fluid overheating, 3��39� Inputs and outputs, 3��63� Instruments in the expanded HOMEmenu, 3��50

� Instruments in the HOME menu, 3��34� Lubrication, 3��42, 3��60� Operating data, 3��53� Power reduction, 3��42� Pump status, 3��40� Reverse pumping, 3��40� S transfer tube switch−over, 3��41� Sensors, 3��39� Software information, 3��52� Symbols in the expanded HOMEmenu, 3��51

� Symbols in the HOME menu, 3��35� User settings, 3��56� Vibrator, 3��42

SPC display unit, 3��27� Operating elements, 3��24, 3��27

Starting pumping, 6��12

Static base structure, 3��11, 5��7

Stationary delivery line, 5��18� Danger zone, 5��19� Downpipe, 5��25� Fastening, 5��22� Fixed point, 5��23� Horizontal, 5��22� Instructions for laying the line, 5��20� Riser, 5��25� SK delivery line system, 5��26� Vertical and inclined, 5��24

Stationary machines, 2��26� Lifting machines, 2��27� Loading, 2��27� Set�up site, 2��26� Stationary placing booms, 2��26� Transporting, 2��27

Stationary placing booms, 2��26

Storm, 2��40

Subject expert, Definition of terms,2��3

Suction cleaning, 6��36

Suction filter, 3��90

Support legs, Description of the func-tions, 3��11

Support legs and support feet, Dan-ger zone, 2��7

Supporting ground, 2��29, 5��12� Corner bearing loads, 2��30


v

Supports, 2��31

Switches off the pump, 4��21

Symbols, 1��3

Symbols for the control system, G��1

TT–delivery pipe with wash–out port,6��31

Technical data, 3��5� Sound power level, 3��8� Sound pressure level, 3��8

Technical terms, G��15

Temperatures, 3��17� Restrictions, 2��40

Test run, 4��6� Diesel engine, 4��7� Machine, 4��7

Towing, 2��34

Transport, 5��1� Chassis, 5��4� Crawler track, 5��7� Driving with an F 8 chassis, 5��4� Driving with an F�25 chassis, 5��4� Driving with an F�80 chassis, 5��5� Loading, 5��1

Transporting, 2��27

Transporting goods, 2��12

Truck mixer, 2��47� Definition of terms, 2��2

Truck mixer driver, 2��47� Definition of terms, 2��3

UUnexpected restart, Agitator safety

cutout, 4��14

VVibrator, 3��94, 4��20

Visual checks, 4��1� Condensate water, 4��3� Functional fluids, 4��2� Hydraulic fluid radiator, 4��3� Hydraulic system, 4��1� Lubrication points, 4��3� Parts in contact with concrete, 4��5� Water box, 4��4

WWarning triangle, orange, Power re-

duction stage 1, 3��37

Warning triangle, red, Power reduc-tion stage 2, 3��37

Wash–out adaptors, 6��30

Water, 2��51

Water box, 4��4� Description of the functions, 3��13

Water hose, Marking, 6��33

Water pump, 3��92

Water pump lever, 3��87

Wind speeds, 2��40

Working area, 2��4, 2��6� Impermissible working area, 2��5, 2��6,2��14

� Permitted working area, 2��5

Working with the machine� Before working with the machine, 2��21� Checking that the machine is ready foroperation, 2��21

� Rendering the machine ready for ope�ration, 2��21

Service Instructionsfor machine operator and maintenance staff

always keep by the machine

Stationaryconcrete pump BSA 1407 D5

Machine no. 214490278

21−09−09

The paper on which this document is printed is 100% chlorine free E Putzmeister Concrete Pumps GmbH 1994

Translation of the original Operating Instructions

Putzmeister Worldwide

Deutsch�landPM

Putzmeister Concrete Pumps GmbHMax−Eyth−Straße 10D− 72631 Aichtal

+49−7127−599−0

+49−7127−599−520

[email protected]

www.putzmeister.de

EspañaPME

Putzmeister Ibérica S.A.Camino de Hormigueras 173Pol. Ind. VallecasE− 28031 Madrid

+34−91−428 81 00

+34−91−428 81 43

[email protected]

www.putzmeister.es

FrancePMF

Putzmeister France3, rue Paul Henri SpaakZAE Jean Monnet77240 Vert Saint Denis

+33−164 64 39 39

+33−164 64 39 29

[email protected]

www.putzmeister.fr

Great BritainPMUK

Putzmeister LimitedCarrwood RoadGB−ChesterfieldDerbyshire S41 9QB

+44−1246−2642 00

+44−1246−26 00 77

[email protected]

www.putzmeister.co.uk

TürkiyePTR

Putzmeister Makine Sanayi ve Tic. A.�G.O.Pa�a Mah.Nam�k Kemal Bulvar� No: 659500 Çerkezköy / TEK�RDA�

+90−282−735−1000

+90−282−738−1001

[email protected]

www.putzmeister.com.tr

USAPMA

Putzmeister America1733 90th StreetSturtevant, WI 53177 USA

+1−262−886−3200

+1−262−886−3212

[email protected]

www.putzmeister.com

South AfricaPMSA

Putzmeister S.A. (Pty) Ltd.Cnr. Bramm & Citrus St. HoneydewP.O.Box 5146 ZA 2118 CrestaSouth Africa

+27−11−794−37 90

+27−11−794−41 19

[email protected]

www.putzmeister.co.za

IndiaPCM

Putzmeister Concrete Machines Pvt LtdPlot No. N4, Phase IVVerna Industrial Estate, Verna SalceteGoa−403722

+91�832�6696000

+91�832−6696300

[email protected]

www.pmw.co.in

JapanPMJ

Putzmeister Japan Co. Ltd.

7−4 Misawa, Tomisato−shiChiba 286−0225, Japan

+81−476−36−8907

+81−476−36−8908

[email protected]

www.putzmeister.jp

KoreaPMK

Putzmeister Korea Co. Ltd.59 Huimanggongwon−ro, Chungwang−DongShihwa Ind. complex 2 MA 707−1 HOShihung−city, Kyonggi−Do, Korea

+82−31−433−4541

+82−31−498−7230

[email protected]

www.putzmeister.co.Kr

Russ�landPMR

OOO �Putzmeister−Rus�Urgumskaja Straße 4, Geb. 31129343 Moskau, Russia

+7−495−775−22−37

+7−495−775−22−34

[email protected]

www.putzmeister.ru

BP00_030_0911EN

de Übersetzung der Originalbetriebsanleitung

bg Ïðåâîä íà îðèãèíàëíî Ðúêîâîäñòâî çà ðàáîòà

cs P�eklad originálního návodu k obsluze

da Oversættelse af den originale driftsvejledning

el MetÜfrash tou prwtotýpou twn odhgiþn leitourgßaj

en Translation of the original Operating Instructions

es Traducción de las instrucciones de servicio originales

et Algupärase kasutusjuhendi tõlge

fi Alkuperäisen käyttöohjeen käännös

fr Traduction des instructions de service originales

hr Prijevod izvornika naputka za uporabu

hu Eredeti üzemeltetési útmutató fordítása

it Traduzione delle istruzioni d’uso originali

lt Eksploatavimo instrukcijos originalo vertimas

lv Lieto�anas pam�c�bas tulkojums no ori�in�lvalodas

nl Vertaling van de oorspronkelijke gebruiksaanwijzing

no Oversettelse av original brukerhåndbok

pl T�umaczenie oryginalnej instrukcji eksploatacji

pt Tradução das Instruções de funcionamento originais

ro Traducerea instruc�iunilor de func�ionare originale

ru Gthtdjl abhvtzzjuj herjdjlcndf gj ärcgkefnfwbb

sk Preklad originálneho návodu na obsluhu

sl Prevod izvirnih navodil za uporabo

sv Översättning av original instruktionsbok

tr Orijinal kullan�m k�lavuzunun tercümesi

BP00_030_0911EN

Table of contents


I214490278

1 Guide to the Service Instructions 1.1 Foreword 1 — 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 Icons and symbols 1 — 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 Safety regulations 2.1 Basic principle 2 — 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1.1 Exclusion of liability 2 � 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2 Requirements for special work 2 — 2 . . . . . . . . . . . . . . . . . . . . . . .

2.3 Welding 2 — 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4 Working on the placing boom 2 — 5 . . . . . . . . . . . . . . . . . . . . . . . .

2.5 Safety-relevant components 2 — 5 . . . . . . . . . . . . . . . . . . . . . . . . .

2.6 Software 2 — 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.7 Protective and safety equipment 2 — 6 . . . . . . . . . . . . . . . . . . . . .

2.8 Electrical power 2 — 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8.1 General 2 � 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8.2 Electrical components 2 � 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8.3 Power at the construction site 2 � 8 . . . . . . . . . . . . . . . . . . . . . . . . . .

2.9 Hydraulic systems 2 — 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9.1 General 2 � 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9.2 Replacing hydraulic hoses 2 � 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.10 Noise emissions 2 — 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.11 Exhaust fumes 2 — 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.12 Functional fluids 2 — 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.13 Disposal of the machine 2 — 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


II 214490278

3 Safety equipment 3.1 Overview of the safety equipment 3 — 1 . . . . . . . . . . . . . . . . . . . . 3.1.1 Active safety functions 3 � 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.2 Passive safety functions 3 � 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.3 Organizational measures 3 � 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.4 Safety−related parts (SRPs) 3 � 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.5 Safety components 3 � 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.6 Parts with increased maintenance requirements 3 � 4 . . . . . . . . .

3.2 EMERGENCY STOP function 3 — 5 . . . . . . . . . . . . . . . . . . . . . . . . . 3.2.1 Description of the functions 3 � 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2.2 Function check 3 � 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 Agitator safety cutout 3 — 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3.1 Description of the functions 3 � 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3.2 Function check 3 � 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3.3 Acknowledging the agitator safety cutout 3 � 11 . . . . . . . . . . . . . . .

3.4 Separating protective devices 3 — 13 . . . . . . . . . . . . . . . . . . . . . . . . 3.4.1 Description of the functions 3 � 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4.2 Function check 3 � 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5 Grille 3 — 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5.1 Description of�the�functions 3 � 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5.2 Function check 3 � 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6 Plates 3 — 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6.1 Description of�the�functions 3 � 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6.2 Function check 3 � 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 Special modes of operation 4.1 Emergency operation – pump function 4 — 1 . . . . . . . . . . . . . . .

4.2 Agitator emergency operation 4 — 3 . . . . . . . . . . . . . . . . . . . . . . . .

4.3 Recovering the machine after faults occur 4 — 5 . . . . . . . . . . . . 4.3.1 Recovery with on�board equipment 4 � 6 . . . . . . . . . . . . . . . . . . . . .


III214490278

5 Maintenance 5.1 Daily tasks 5 — 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.1 Daily visual checks 5 � 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.2 Function check 5 � 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.3 When pumping 5 � 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.4 After every job 5 � 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 Maintenance work 5 — 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2.1 As required 5 � 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2.2 Regular maintenance tasks 5 � 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3 Residual risks during maintenance, inspection and repair work 5 — 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3.1 Personal protective equipment 5 � 7 . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.2 Personnel requirements 5 � 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.3 Auxiliary devices 5 � 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.4 Residual risks 5 � 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4 General tightening torques 5 — 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4.1 Set screws and nuts 5 � 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4.2 Flared screwed joint, reassembly 5 � 11 . . . . . . . . . . . . . . . . . . . . . . . 5.4.3 Profiled ring joint, reassembly 5 � 11 . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4.4 WALFORMplus threaded union 5 � 12 . . . . . . . . . . . . . . . . . . . . . . . . 5.4.5 WALFORMplus threaded union, reassembly 5 � 13 . . . . . . . . . . . . .

5.5 Functional fluids 5 — 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5.1 Hydraulic fluid 5 � 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5.2 Level of contaminant 5 � 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5.3 Lubricant analysis 5 � 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5.4 Storage of lubricants 5 � 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.6 Lubricant recommendation 5 — 18 . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6.1 Oils 5 � 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6.2 Greases 5 � 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6.3 Hydraulic fluids 5 � 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


IV 214490278

Maintenance cards00−001 Visual checks 5 � 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03−002 Function checks 5 � 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03−010 Changing the hydraulic fluid 5 � 29 . . . . . . . . . . . . . . . . . . 04−002 Hydraulic hoses 5 � 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04−005 Vacuum meter 5 � 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04−013 Changing the pressure filter element 5 � 39 . . . . . . . . . . 04−019 DEF delivery pump filter change 5 � 45 . . . . . . . . . . . . . . 06−023 Delivery piston replacement 5 � 49 . . . . . . . . . . . . . . . . . . 07−069 Replacing the transfer tube bearing 5 � 55 . . . . . . . . . . . 07−070 Replacing the switching shaft bearing

(flanged bearing) 5 � 61 . . . . . . . . . . . . . . . . . . . . . . . . . . . 07−071 Replace the spectacle wear plate 5 � 77 . . . . . . . . . . . . . 07−072 Replacing the S�transfer�tube 5 � 91 . . . . . . . . . . . . . . . . . 07−073 Replacing the S�transfer�tube wear sleeve 5 � 99 . . . . . 07−074 Replacing the thrust ring and wear ring 5 �107 . . . . . . . . 07−075 Adjusting the S�transfer�tube 5 �113 . . . . . . . . . . . . . . . . . 07−078 Resolver on the switching shaft 5 �127 . . . . . . . . . . . . . . . 08−007 Lubrication 5 �129 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10−007 Measuring the wall thickness

(Machines with S�transfer tube) 5 �131 . . . . . . . . . . . . . . . 10−044 Measuring the wall thickness of two−layer pipes 5 �137

Index of key words

Guide�to�the�Service�Instructions

1��IBP01_009_1011EN

1 Guide to the Service Instructions

This chapter contains notes and information that will help you to usethese Service Instructions. Do not hesitate to contact us if you haveany queries:

Putzmeister Concrete Pumps GmbHAfter Sales departmentMax�Eyth�Str. 1072631 AichtalTelephone: +49 (0) 7127 5990Fax: +49 (0) 7127 599 520E�mail: [email protected] contact the branch or works agency that is responsible for you.

Address:

Telephone:

Fax:

E�mail:


1��II BP01_009_1011EN


1��1BP01_010_1011EN

The Service Instructions contain important information about themaintenance of the machine. Observing these instructions helps toavoid danger, to reduce repair costs and downtimes, and to increasethe reliability and service life of the machine.

The Service Instructions must be supplemented by the relevantnational rules and regulations for accident prevention and environ�mental protection.

The Service Instructions must always be available wherever the ma�chine is in use.

These Service Instructions must be read and applied by any personin charge of carrying out work with or on the machine, e.g.− in operation, including setting up, fault rectification in the course of

work, removal of production waste, care and disposal of fuels andconsumables;

− maintenance (servicing, inspection, repair) and/or− Transport.

In addition to the Service Instructions and mandatory rules and re�gulations for accident prevention in the country and place of use ofthe machine, the generally recognized rules of technology for safeand proper working must be observed.

1.1 Foreword


1��2 BP01_010_1011EN

Should you have any questions after studying the Service Instruc�tions, the branch or agency serving you, or the Aichtal Works, will behappy to provide you with more information.

You will make it much easier for us to answer any questions if youcan give us the details of the machine model and the machinenumber.

These Service Instructions describe the vehicle superstructure only.The Operating Instructions issued by the vehicle manufacturer applyfor the vehicle itself.

In the interests of constant improvement, modifications are madefrom time to time and it may be the case that we were unable to takethese into consideration when these Service Instructions wereprinted.

In the event of any amendment, the copy of the Service Instructionsthat is intended for the machine will be replaced in full.

The reproduction, distribution and utilization of this document as wellas the communication of its contents to others without explicit author�ization is prohibited. Offenders will be held liable for the payment ofdamages. All rights reserved in the event of the grant of a patent,utility model or design.

© Putzmeister Concrete Pumps GmbH 1994


1��3BP01_003_0601EN

The following icons and symbols are used in the OperatingInstructions:

" Task symbolText following this symbol describes tasks which you are required towork through from top to bottom in the sequence shown.

� Text following this symbol describes the result or effect of an action.

See also the maintenance cards:This icon is used to refer to the maintenance cards required,possibly as a supplement to the maintenance card you are currentlyreading.

The following special tools are required:This icon identifies the special tools necessary to carry out the work.Normal tools, i.e. commercially−available tools or tools carried in thetruck, are not specially listed.

Environmental protectionParticular specifications regarding environmental protection areintroduced by the icon shown, the words �Environmental protection"printed in bold, and a line. The associated text is printed in italicsand ends with another line.

NoteParticular information regarding the economic use of the machine isintroduced by the icon shown, the word �Note" printed in bold, anda�line. The associated text is printed in italics and ends with anotherline.

CautionParticular information or rules or prohibitions intended to preventdamage are introduced by the icon shown, the word �Caution"printed in bold, and a line. The associated text is printed in italicsand ends with another line.

1.2 Icons and symbols


1��4 BP01_003_0601EN

DangerParticular information or rules or prohibitions intended to preventpersonal injury or significant damage are introduced by the iconshown, the word �Danger" printed in bold, and a line. The associatedtext is printed in italics and ends with another line.

The appropriate icon will be used if it is possible to identify the sourceof the danger precisely.

Danger of fireThis icon is used to identify actions for which there is a particulardanger of fire.

Danger of explosionThis icon is used to identify actions during which there is the dangerof an explosion. The explosion may also be caused by pressurebeing released suddenly.

Falling items�This icon is used to identify actions in which there is a risk of injurycaused by parts falling down.

Danger of crushingThis icon is used to identify actions during which there is the dangerof being crushed.


1��5BP01_003_0601EN

Suspended loadThis icon is used to identify actions in which suspended loads mayfall down.

High voltageThis icon is used to identify actions in which there is the danger ofelectrocution, possibly with lethal consequences.

Danger of burningThis icon is used to identify actions in which there is a danger ofburning from chemical substances which are not specificallydescribed.

Danger of burningThis icon is used to identify actions in which there is a danger ofburning from battery acid.

Danger of poisoningThis icon is used to identify actions in which there is a danger ofpoisoning by inhalation of gases, ingestion of or contact withsubstances.


2��IBP03_083_1701EN

2 Safety regulations

These safety regulations conform to the chapter �Maintenance andspecial work" in the VDMA brochure

�Safety manual Concrete delivery and placing machines".

The safety regulations in the Operating Instructions must also be fol�lowed for all maintenance and special work.

NoteSpecial safety regulations may be necessary for some tasks. Thesespecial safety regulations will only be found in the description of theparticular task.

We include here a listing of regulations and safety standards for yourinformation:� EN 12001, Conveying, spraying and placing machines for con�

crete and mortar� EN 12100, Safety of machinery,� EN 60204−1, Electrical equipment of machines.� In the Federal Republic of Germany: DGUV�Regulation�101−012,

Concrete pumps and placing booms.


2��II BP03_083_1701EN


2��1BP03_084_1011EN

The safety regulations in the Operating Instructions for this machineapply whenever the machine is operated.

DangerThere is an increased risk of accidents during a special operation.You may only carry out the activities described in these service in�structions if:� you have been trained for these activities by the machine manu�

facturer� you have been authorized for these activities by the machine oper�

ating company

We state here expressly that Putzmeister accepts no liability for dam�age arising from incorrect or negligent operation, servicing or main�tenance or as a result of use contrary to the designated use. Thisstatement is particularly valid for modifications to, additions to andcustomization of the machine that are liable to compromise safety.The guarantee will no longer be valid in such cases.

2.1 Basic principle

2.1.1 Exclusion of liability


2��2 BP03_085_2101EN

In the capacity of operator, it is your responsibility to provide all thenecessary information to the personnel concerned before specialwork or maintenance work is carried out. Someone should be nomi-nated as the person responsible for this.

Carry out the maintenance and inspection operations and complywith intervals specified in the Operating Instructions, including speci-fications for the replacement of parts and equipment. These tasksmay only be carried out by qualified personnel.

Workshop equipment appropriate to the task in hand is absolutelynecessary for the execution of maintenance work.

If changes have been made to the machine, it must be checked by asubject expert before recommissioning.

Secure a wide area around the maintenance area as far as is neces-sary.

A machine completely shut down for maintenance and repair workmust be secured against being restarted inadvertently:– Lock the main control devices and remove the key.– If a main switch is fitted, attach a warning plate to it.

Only carry out maintenance work if the machine is parked on leveland sufficiently supporting ground and is secured to prevent it rollingaway.

Use specially designed or otherwise suitable climbing aids and wor-king platforms when carrying out assembly work above head height.Never use machine parts as climbing aids. Keep all handgrips,steps, railings, platforms and ladders free from dirt, snow and ice.

2.2 Requirements for spe-cial work


2��3BP03_085_2101EN

Carefully secure individual parts and large assemblies to lifting gearwhen carrying out a replacement operation. Use only suitable andtechnically perfect lifting gear and suspension systems with ade-quate lifting capacity. Never stand under suspended loads.

Attachment of loads and signalling to crane operators should only beentrusted to experienced personnel. The signaller must be withinvisual range of or in voice contact with the crane operator.

Observe national regulations when working with lifting gear.

Work on chassis, braking and steering systems must only be carriedout by qualified personnel trained for such work.

Clean any traces of oil, fuel or preservatives from the machine, es-pecially connections and threaded unions, before carrying out main-tenance or repair work. Do not use aggressive cleaning agents. Uselint–free cleaning rags.

Bolted connections that you have loosened for carrying out mainte-nance and repair work must always be replaced or retightened inaccordance with manufacturer specifications.

Do not open gas–filled spring elements, as used on maintenanceflaps, for instance. The spring elements are filled with gas underhigh pressure which can escape explosively if you attempt to openthem. Relieve the tension on systems under mechanical stress.

Be aware of hot functional fluids and surfaces (hydraulic fluid, hy-draulic fluid radiator, etc.).

Ensure that all functional fluids, consumables and replaced parts aredisposed of safely and with minimum environmental impact.


2��4 BP03_085_2101EN

Only carry out welding, flame cutting and grinding operations on themachine once this has been expressly approved by the manufactu-rer.

Only qualified personnel may carry out welding work in line with ma-nufacturer specifications, especially on the placing boom, on thesupports, on load–bearing parts, on fuel and oil tanks or other com-ponents which are important for industrial safety. This work must beinspected by qualified welding personnel. The operator must docu-ment the evidence of the formal qualifications of the welder and thequalified welding personnel.

Always attach the earth cable of the welding unit directly to the com-ponent which is being welded. The welding current must not flowthrough hinges, cylinders, etc. Significant damage may be caused inthe event of a flash over.

wz0215

Electronic components can be destroyed by stray voltage during arcwelding processes. For this reason:– Disconnect the remote control cable from the control console.– Disconnect all cables leading to the receiver of the radio remote

control system.– Close connector sockets with caps.– Disconnect the positive and negative leads from the battery.

Clean the machine and its surroundings of dust and flammable sub-stances and make sure that the premises are adequately ventilatedbefore carrying out welding, flame-cutting and grinding operations,otherwise there is a risk of explosion.

2.3 Welding


2��5BP03_085_2101EN

Only carry out maintenance and repair work on the placing boom ifthe placing boom is folded or properly supported, the engine is swit-ched off and the support legs are secured.

Support the placing boom arms before starting work on the valves,cylinders or hydraulic lines on the boom.

The delivery line was installed without tension with the placing boomin the driving position and can only be replaced without difficulty inthis condition. Stresses may be generated on folding if the deliveryline is replaced when the placing boom is unfolded.

Do not remove the entire delivery line but rather replace it bit by bit,e.g. replace the boom arm with a new boom arm. Otherwise, the pi-vot points of the new delivery line will have to be redetermined usingspecial equipment.

Work on safety–relevant components requires particular specialistknowledge.

The following activities in particular must only be carried out by qua-lified personnel that have been authorised by the manufacturer:– Repairing, replacing or adjusting safety–relevant components and

adjustable devices (pressure limiting valves, potentiometers, fluidflow limiters, hydraulic cylinders, sensors, etc.)

– Removing lead seals

Modifications to the machine data (in particular, increasing pressu-res, modifying speeds, etc.) are not permitted.

2.4 Working on the pla-cing boom

2.5 Safety-relevant com-ponents


2��6 BP03_085_2101EN

If a machine is equipped with software, the software may only beused as is provided for in the manufacturer’s Operating Instructions.

Only persons authorized by the manufacturer may intervene in themachine’s software. This also applies to updates.

Unauthorized interventions in the machine’s software may lead tosevere damage and accidents.

Any safety equipment removed for maintenance purposes must berefitted and checked immediately upon completion of this work.

All equipment required for safety and accident prevention (warningsigns and information plates, grilles, guards, etc.) must be in place.Such equipment must not be removed, modified or damaged.

Keep all warning signs and information plates on the machine com-plete and in a perfectly legible condition.

It is your responsibility as operator to ensure that any warning signsand information plates that have been damaged or rendered illegibleare replaced without delay.

2.6 Software

2.7 Protective and safetyequipment


2��7BP03_085_2101EN

2.8 Electrical power

Work on electrical systems or operating equipment must only becarried out by qualified personnel. For further information on machi-nes operated on the site power supply, see also section 2.8.3, entit-led “Power at the construction site”.

wz0235

Machine components which are to undergo maintenance work mustbe de-energized. Ensure that disconnected machine componentscannot be restarted. First of all, you must check that de-energizedparts are indeed de-energized, then earth and short-circuit them andisolate adjacent live parts.

Disconnect the negative lead from the battery before starting anywork on the electrical system of machines with an internal combus-tion engine. When reconnecting, connect the positive terminal first,and then the negative terminal.

Before starting work on high-voltage assemblies and after cuttingthe power supply, you must connect the supply cable to earth andshort-circuit the components, particularly the capacitors, with a rod-type earth electrode.

If work is to be carried out on live parts, the presence of a secondperson is required who can switch off the power supply to the ma-chine in the event of an emergency. Secure the working area with ared–and–white safety chain and a warning plate. Use insulated toolsonly.

2.8.1 General


2��8 BP03_085_2101EN

Control cabinet, motor and control elements are protected as stan-dard in accordance with degree of protection IP 54. IP 54 means:– Complete protection against contact with live components or inter-

nal moving parts. Protection against damaging dust deposits.– Water spraying on the equipment from random directions must not

have a damaging effect.

Only use original fuses with the specified voltage rating. Bridging orthe use of fuses with too high a rating can irreparably damage theelectrical system. You must switch off the machine immediately if afault occurs in the power supply.

The power on the construction site must be supplied from a specialfeed point (construction site power distribution point). Machines withan electric motor must not be connected to the mains power supply.

Only trained and qualified personnel are permitted to work on electri-cal systems with an operating voltage of more than 25 volts alterna-ting voltage or 60 volts direct current. Only such qualified personnelmay install, connect, disconnect and open electrical control cabinets.

An electric shock (possibly with fatal consequences) may be the re-sult of touching machines with electric motors or contact with otherelectrical cables if the electrical connection has not been made pro-perly or the supply cable is damaged.

2.8.2 Electrical components

2.8.3 Power at the con-struction site


2��9BP03_085_2101EN

2.9 Hydraulic systems

Work on hydraulic systems must only be carried out by qualified per-sonnel.

Always wear your personal protective equipment when carrying outwork on the hydraulic system. Escaping fluid is toxic and can pene-trate the skin.

wz0245

Injection through the skin is a major medical emergency. In theevent of injuries caused by pressurized fluid, inform the companymedical officer and call a medical specialist immediately. This alsoapplies for injuries which may seem only slight. Hydraulic fluid whichhas penetrated underneath the skin must be removed immediately.Otherwise, there is a risk of death due to impaired blood circulationand infections.

Parts of the system and pressure lines which are to be opened (hy-draulic, pneumatic and delivery lines) must be depressurized accor-ding to assembly descriptions before repair work is started.

Work only on depressurized systems. Switch the hydraulic pumpdrive and the engine off, as there is otherwise a risk of injury causedby functional fluids escaping under pressure. Where a hydraulic ac-cumulator is fitted, open the accumulator dump valve to prevent anymovements of the machine as a result of the residual pressure. Mo-difications to the hydraulic accumulator are prohibited.

Be aware that enclosed hydraulic fluid can remain under pressurefor a certain length of time. Do not open any hydraulic systems ifthey are under load from an external force (particularly from a raisedplacing boom).

2.9.1 General


2��10 BP03_085_2101EN

Lay and install hydraulic lines in accordance with the current rules ofengineering. Connections must be fitted at the appropriate points.Fittings and the length and quality of the hoses must comply withrequirements.

You must carefully vent the hydraulic system after any maintenancework, as there is otherwise a risk of injury caused by swinging andtelescopic support legs extending rapidly, the placing boom lowe-ring, etc. Open vent valves very carefully until hydraulic fluid starts toescape. You should on no account open vent valves further than ne-cessary or go so far as to remove them.

Damaged hydraulic lines must be replaced rather than repaired. Youmust replace damaged or saturated hydraulic hoses immediately.Hydraulic fluid spray escaping under pressure can cause injuriesand fires.

During retesting, hydraulic hoses must be checked by a subject ex-pert for external damage. The retest must be recorded in the checkbook. The operator must have hydraulic hoses replaced if they showsigns of external damage.

The place of work in normal operation is with the remote control. Forthis reason, it is not possible to specify a particular place of work forthe machine operator. Take the values for the sound pressure leveland sound power level from the machine Operating Instructions.

Wear suitable personal protective equipment in the vicinity of themachine.

As the operator, you must instruct your personnel to always weartheir personal ear protection. You are responsible for ensuring thatyour personnel comply with this regulation.

All soundproofing equipment must be fitted and in perfect condition.All soundproofing equipment must be closed during operation. Ahigh sound level can cause permanent hearing damage.

2.9.2 Replacing hydraulichoses

2.10 Noise emissions


2��11BP03_085_2101EN

Vehicle exhaust gases contain constituents which can be lethal orcarcinogenic. Operate internal combustion engines and fuel–opera-ted heating systems only in adequately ventilated premises. Beforestarting up the engine in enclosed spaces, make sure that there isadequate ventilation and direct the exhaust gases away from theplace of work.

Wear personal protective clothing and equipment for all work inwhich exhaust gases or particles of building material can enter thebody through the respiratory passages. Comply with the informationissued by the manufacturer of the building material.

When handling oils, greases and other functional fluids, observe thesafety regulations applicable to the product concerned (see the sa-fety data sheet).

Oils, fuel and other functional fluids may be hazardous to healthupon contact with the skin, etc. You must, therefore, always wearpersonal protective clothing and equipment when you are handlingtoxic, caustic or other functional fluids that are hazardous to healthand always take note of the manufacturer’s information.

wz0146

Take care when handling toxic and caustic functional fluids (brakefluid, battery acid, water glass, concrete set accelerating admixtures,cement, etc.). Building materials containing cement have a highlyalkaline effect when they react with water (and also with perspira-tion). Concrete additives are toxic and caustic.

2.11 Exhaust fumes

2.12 Functional fluids


2��12 BP03_085_2101EN

Cleaning agents, concrete release agents, preserving agents etc.propelled by compressed air can cause very serious damage to therespiratory tract if a respiratory protection mask is not worn. Spraymist enters the lungs very easily.

Frequent injuries are eye injuries caused by concrete spatter, waterglass or other chemical substances.

Take care when handling hot functional fluids and consumables (riskof burning or scalding).

Have used operating equipment and functional fluids such as filters,batteries, oil, brake fluid, etc. disposed of properly. Used cleaningrags should also be disposed of properly.

wz0186

To dispose of the machine, you must proceed in accordance with allpoints in the disposal regulations which apply in your country. Duringthe disposal operation, you must observe the following in particular:– Remove the functional fluids, particularly hydraulic fluids, engine

oils, fuel, brake fluid, concrete admixtures, any environmentallyhazardous functional fluids or functional fluids which are hazar-dous in any other way, and dispose of these correctly.

– Remove the operating equipment, particularly the hydraulic fluidreservoir, hydraulic cylinder, hydraulic fluid radiator, hydraulic linesand hoses and other components which may contain residualfunctional fluids, and dispose of these correctly.

– Remove the steel structure and dispose of it correctly, e.g. by re-cycling.

– Dispose of the truck or the drive unit correctly.

2.13 Disposal of the ma-chine

Safety�equipment

3��IBP15_001_1202EN

3 Safety equipment

The safety equipment on the machine is described in this chapter. Inparticular, it contains information about− Intervals for inspection by subject experts− Intervals for function checks

Safety�equipment

3��II BP15_001_1202EN

Safety�equipment

3��1AP15_002_1701EN

Depending on the type of machine and its equipment, the followingsafety equipment may be fitted. Please see the machine card for de�tails about which safety equipment your machine has been fittedwith. Carry out checks on the existing safety equipment according tothe following descriptions within the specified intervals.

3.1.1 Active safety functions

Intervals for inspection by asubject expert

Interval for function check

EMERGENCY STOP function annually Before the machine is usedeach time

Agitator safety cutout annually Before the machine is usedeach time

3.1.2 Passive safety functions



Separating protective de�vices

annually each time a separating pro�tective device is removed

Grille annually Once a month

3.1.3 Organizational measures



Plates annually Once a month

3.1 Overview of the safetyequipment

Safety�equipment

3��2 AP15_002_1701EN

3.1.4 Safety–related parts (SRPs)

DangerIncorrect assembly of safety−related parts can result in malfunctions.This creates a risk of death.Safety−related parts (SRP) should only ever be repaired, maintainedor replaced by qualified personnel with the necessary authorisation.

Safety�related parts (SRP) are components that ensure the safety ofthe machine functions. They are specially marked on spare partssheets. When a spare part that can be used as an SRP is ordered, itis delivered in separate, clearly labelled packaging.

Read the �EB00−5−xxxxx−xxxx" sheet to ensure that you are aware ofthe SRPs fitted on the machine.

AP15_002_1701EN 1

3

Spare parts sheet Spare part packaging

SRP marking

Safety�equipment

3��3AP15_002_1701EN

AP15_002_1701EN 2

1 2 3 4 5

Pos.0 Illustration Meaning

1 Character: Asterisk �*" Item not available for order

2Character: Exclamation mark�!"

Safety−related part (SRP)

3 NumberService life of the SRP [years]e.g. �10" = 10 years

4 Symbol: �Hourglass" Service life of the SRP

5 GraphicExample illustration: Spare parts sheet�EB00−5 XXXXX−XXXX" Safety−related parts

NotePutzmeister specifies a service life�(3) for every safety−related part.SRPs must be replaced once this service life has elapsed.

Safety�equipment

3��4 AP15_002_1701EN

3.1.5 Safety components

The following listed parts are defined as safety components. This in�cludes the following components in particular:− Pressure limiting valves

DangerIncorrect assembly of components can result in malfunctions.This creates a risk of death.Safety components should only ever be repaired, maintained or re�placed by qualified personnel with the necessary authorisation.

3.1.6 Parts with increased maintenance requirements

The following listed parts are defined as parts with increased main�tenance requirements. This includes the following components inparticular (depending on the machine):− Accumulator− Accumulator bladder− Gas valve insert for accumulator

DangerIncorrect assembly of parts with increased maintenance require�ments can result in malfunctions.This creates a risk of death.Components with increased maintenance requirements should onlyever be repaired, maintained or replaced by qualified personnel withthe necessary authorisation.

Safety�equipment

3��5AP15_001_1701EN

3.2 EMERGENCY STOP function

ISO�13849�1:2015 category�1 PL�c


annually

Intervals for function checks Before the machine is used each time

As soon as an EMERGENCY STOP button is pressed, all dangerousmachine movements stop. The following actions are triggered whenthe relevant components are present on the machine:

Area Safety action

Pump − The agitator stops,− The change�over valve is de−energized,− The accumulator dump valve is opened and the

accumulator (if fitted) is emptied,− The transfer tube stops,− The variable main pump swings back, and the

delivery pistons stop.

Cable remotecontrol

− The supply voltage to the cable remote controlsystem, with the exception of that for the horn,is switched off.

Control cabi-net

− The �EMERGENCY STOP" symbol is high�lighted in colour and flashes in the display unit.

3.2.1 Description of thefunctions

Safety�equipment

3��6 AP15_001_1701EN

It is only possible to intervene quickly in the event of danger if all theEMERGENCY STOP buttons are working properly.

" Switch the pump and agitator on.

" Press one of the EMERGENCY STOP buttons.� The agitator must come to a halt immediately.� The variable main pump swings back, and the delivery pis�tons stop.

" Check all EMERGENCY STOP and STOP buttons on the ma�chine and on the remote control in the same way.

3.2.2 Function check

Safety�equipment

3��7AP15_003_1609EN

3.3 Agitator safety cutout



annually






Safety�equipment

3��8 AP15_003_1609EN

This machine is fitted with an agitator safety cutout (RSA). As soonas you open the grille, the signal between the transponder and read�ing head is broken. This causes the agitator to halt and the pressureto be dumped from the accumulator (if fitted) or the change−overvalve to be de−energized, i.e.� the transfer tube will no longer beable to switch over. In addition, the delivery pistons return to the endposition and the concrete pump halts.

AP15_003_1609EN 1

1 2 3

Pos.0 Designation

1 Reading head (on the hopper − example illustration)2 Green and red LEDs3 Transponder (on the grille)

Safety action:− The agitator stops.− The accumulator dump valve (if fitted) is opened and the accumu�

lator (if fitted) is emptied− The change−over valve is de−energized (depending on the ma�

chine)− The transfer tube stops.

Technical action:− The delivery pistons return to the end position− The concrete pump stops


Safety�equipment

3��9AP15_003_1609EN

AP15_003_1609EN 2

" Open the grille with the concrete pump running.� The transponder signal is broken.� The agitator must come to a halt immediately.� The transfer tube must no longer switch over.� The concrete pump must run to the end position and halt.


Safety�equipment

3��10 AP15_003_1609EN

Safety action:� The agitator must come to a halt immediately.� The hydraulic fluid pressure in the accumulator (if fitted) isdumped (see the pressure gauge).� The change−over valve is de−energized (depending on themachine).� The transfer tube must no longer switch over.

Technical action:� The concrete pump must run to the end position and halt.

NoteThe LEDs on the evaluation device indicate the following information:� The green LED flashes for 8�seconds during the initialization pro�

cess.� The green LED lights up during normal operation when the grille is

closed.� The green LED flashes when the grille is open.� The red LED lights up when there is a fault with the evaluation de�

vice.

Safety�equipment

3��11AP15_003_1609EN

The agitator is secured against unexpected restarts. When the ma�chine is set up, and when the agitator safety cutout is triggered, itmust be acknowledged on the control cabinet before the concretepump can be switched back on.

DangerRisk of injury when the agitator is operating and the transfer tube isswitching. Before acknowledging the agitator safety cutout, checkthat no�one is in any danger.

NoteYou must first acknowledge the agitator safety cutout on the controlcabinet and switch the concrete pump off and on again before re�starting the agitator.

3.3.3 Acknowledging theagitator safety cutout

Safety�equipment

3��12 AP15_003_1609EN

AP15_003_1609EN 3

1

Pos.0 Designation

1 Toggle switch on the control cabinet:Acknowledge the agitator safety cutout

" Activate the �Acknowledge the agitator safety cutout" toggleswitch.

Safety�equipment

3��13AP15_004_1701EN

3.4 Separating protective devices



annually


A protective device is an obstacle (e.g.�cover) located between themachine operator and the danger zone.

Below you will see an example figure of a stationary concrete pumpand the separating protective devices fitted.

" Check whether the protective devices are present, fully func�tional and securely mounted.



Safety�equipment

3��14 AP15_004_1701EN

AP15_004_1701EN 1

1 2 3 4

6 57


Pos. 0 Safety equipment

1 Covers over the switch cylinders2 Side protection doors3 Exhaust guard4 Grille on V−belt (depending on the machine)5 Water box cover6 Spray guard7 Grille on the hopper

Safety�equipment

3��15BP15_009_1608EN

3.5 Grille

ISO�13849�1:2015 category�2 PL�d


annually

Intervals for function checks Once a month

Intervals for replacementAs soon as a bar has a residual material thickness of 50% ofheight or width, at any point.

The grille is a passive safety function (protective device). For techni�cal reasons, the bar spacing is selected in such a way that allowsconcrete with defined particle sizes to flow into the hopper. The barsare subject to natural wear.

DangerIf the grille is defective, there is a risk that the operator could becaught in the agitator and seriously injured. Therefore, make surethat the grille remains fully functional at all times. If the residual ma�terial thickness is reached, you must have the grille replaced byqualified personnel authorized by Putzmeister.

Once the grille has been replaced, the agitator safety cutout must bereset. This may only be performed by qualified personnel authorizedby Putzmeister.

3.5.1 Descriptionof the functions

Safety�equipment

3��16 BP15_009_1608EN

BP15_009_1608EN 1

" Measure the width�(W) and height�(H) of the bars in an areawith high wear, preferably in the middle of the grille.

" Measure the width�(W) and height�(H) of the bars in an areawith low wear (the edge of the grille).

" Compare the values measured.

NoteYou must have the grille replaced if one of the residual material thick�nesses is less than 50% of the original material thickness.

" Inspect the grille for any other damage (broken bars, crackedseams, etc.).

NoteYou must have the grille repaired or replaced if you detect any dam�age.


Safety�equipment

3��17BP15_010_1202EN

3.6 Plates


annually

Intervals for function checks Once a month

Plates on the machine warn operators of dangers that cannot be pre�vented by means of the design.

NoteYou will find the locations of the plates on the machine circuit dia�grams, which indicate which plate should be affixed where.


" Check whether the plates that are required according to theplate location plan have been affixed on the machine and arelegible.

" Replace any missing, damaged or illegible plates with newones.

3.6.1 Descriptionof the functions

Safety�equipment


Special�modes�of�operation

4��IAP16_001_1609EN

4 Special modes of operation

The machine’s special operating modes are described in thischapter. Special operating modes are, in particular:− Operation in situations of increased risk− Operation with limited functions

DangerThere is an increased risk of accident during special operation.Special operation must only be carried out if:� You have been trained for these activities by the machine manu�

facturer� You have been authorized for these activities by the machine oper�

ating company


4��II AP16_001_1609EN


4��1AP16_004_1609EN

The hydraulic control valves are built into the pump control system.They are only for emergency manual operation of the machine whenthe control system fails.

NoteFor the location of the pump control system, refer to the overview atthe start of the chapter �General technical description".Familiarize yourself with the functions of the pump control system byreading the notices affixed to it.

AP16_004_1609EN 1

Pos.0

Designation


4.1 Emergency operation– pump function

Example of OPSpump control system


4��2 AP16_004_1609EN

Operating the OPS pump control system

In order to be able to move the piston to the cylinder end position,operate the drive cylinder�emergency operation (2).

In order to be able to switch over the transfer tube, keep the drivecylinder emergency operation (2) pressed, while at the same timeoperating the transfer tube emergency operation (1).

NotePress and hold the drive cylinder emergency operation and thetransfer tube emergency operation until the transfer tube switchesover.

Drive cylinder emerg�ency operation

Emergency operation �transfer tube


4��3AP16_002_1609EN

If the control panel has failed, you can use different directions ofrotation to manually operate the agitator from the hydraulic controlblock illustrated below.

NoteThe water pump lever must be in the zero position so that the fluidflow is directed to the agitator control block.

NoteHow the emergency operation devices are assigned may vary de�pending on the mounting position. It may also be the case that thecontrol block is installed rotated through 90°. Familiarize yourselfwith the functions of the control block by reading the notices affixedon site.

4.2 Agitator emergencyoperation


4��4 AP16_002_1609EN

Operating the agitator emergency operation device

AP16_002_1609EN 1

1

2


Pos.0 Designation

1 Agitator�on − agitation direction away from the delivery cyl�inder

2 Agitator�on − agitation direction towards the delivery cylin�der

" To change the agitator’s direction of rotation manually, actuateone of the emergency operation devices.


4��5AP16_003_1701EN

If a fault occurs on the machine and cannot be rectified immediately,you must stop site use and take steps to recover the machine. Thedelivery system may become damaged if concrete sets in it.

NoteRecovery of the machine is a special operating mode. This specialoperating mode is not suitable for continuing site use.

DangerThere is an increased risk of accident during special operation.Special operation must only be carried out if:� You have been trained for these activities by the machine manu�

facturer� You have been authorized for these activities by the machine oper�

ating company

The machine’s EMERGENCY STOP buttons do not work while themachine is being recovered (e.g. in the event of a power failure). Forthis reason, you must cover all EMERGENCY STOP buttons for theduration of machine recovery.

Have a second person help you, as the steps required can be bettercarried out with two people.

4.3 Recovering the ma-chine after faultsoccur


4��6 AP16_003_1701EN

As long as the machine’s hydraulic drive unit is working, you can re�cover the machine using on�board equipment.

The pump control system is equipped with hydraulic control valveswhich can be operated by hand. They are only for emergency man�ual operation of the machine when the control system fails.

AP16_003_1701EN 1

Pos.0 Designation


4.3.1 Recovery with on-board equipment

Emergency operation– pump function

Example of OPSpump control system


4��7AP16_003_1701EN

" Press the drive cylinder emergency operation device to the leftor right.� The corresponding delivery cylinder starts to move.

On machines with a �single−circuit hydraulic system", you can switchover the transfer tube as follows:

" Press and hold the drive cylinder emergency operation device.At the same time, actuate the transfer tube emergency oper�ation device.� The transfer tube switches over.

NotePress and hold the drive cylinder emergency operation and thetransfer tube emergency operation until the transfer tube switchesover.

" Pump the concrete out of the delivery line, back into thehopper.

" Clean the delivery line as described in the �Cleaning" sectionof the �Pumping operations" chapter.

" Clean the hopper, delivery cylinder and S transfer tube as de�scribed in the �Cleaning" section of the �Pumping operations"chapter.

NoteIf the machine breaks down completely, please contact the Putzme�ister After Sales department. The service technician will tell you whatyou can do to recover the machine.



Maintenance

5��IBP09_001_9405EN

5 Maintenance

In this chapter you will find information on maintenance work which isnecessary for the safe and efficient operation of the machine.

Following the general maintenance information, you will find themaintenance cards necessary for this machine. The table of contentsincludes a summary of the maintenance cards in numerical order,you will find an alphabetical summary in the Index of key wordsunder the entry for �Maintenance cards".

We should like here to emphasise expressly that all prescribedchecks, inspections and preventative maintenance work must beconscientiously carried out. Otherwise, we will refuse to accept anyliability or to honour the warranty. Should you ever be in any doubt,our After Sales Department is always ready to give you advice andassistance.

Maintenance

5��II BP09_001_9405EN

Maintenance

5��1AP09_002_0308EN

You must carry out daily checks, function checks and maintenancetasks so that your machine remains fully functional and is safe inoperation. The tasks are described in detail in the �Cleaning" sec�tions of the �Safety regulations" and �Pumping operations" chapters.The following tables summarize these once more. The criterion col�umn briefly describes the points you need to observe. The checksmust be carried out at the beginning of each new shift in the case ofmachines in continuous operation.

CautionYou must rectify (or have rectified) any defects immediately youdiscover them during your checks.

You must lubricate your machine and check it each time before youstart to use it.

Assembly Checking Criterion

GeneralSafety devices available and in a fully functioning

conditionGeneralLubrication points sufficient lubrication

Engine Oil level sufficient

Agitator gearbox Oil level sufficient

Oil level sufficient

Hydraulic system Condensation in the hydraulic fluidreservoir drain off if present

Radiator Contamination sufficient cooling possible

Spacer flange securing wire undamaged securing wire

Water boxWater level The piston rods must be completely

covered

Water contamination no hydraulic fluid or concrete in thewater box

Transfer tubeInner wall and wear ring no mechanical wear

Transfer tubeSpectacle wear plate no mechanical wear

Centralized lubrica� Pipes no leaks or fracturesCentralized lubrication system Grease gun sufficient grease reserve

Delivery line Suitability and weardesigned for the delivery pressure, laidaccording to the rules of technology,wall thickness sufficient

Compressor Oil level sufficient

5.1 Daily tasks

5.1.1 Daily visual checks

Maintenance

5��2 AP09_002_0308EN

You must always check all the control and monitoring functions plusthe stroke times of the pump before using it.

Assembly Function checks and inspections Criterion

Measure stroke times compare against test reading

General Engine start up/engine off fully functional

All operating elements fully functional

Vacuum meter for the suction filters in the green zone

Red button for the pressure filters red button remains depressed

Hydraulic systemAgitator cut−out fully functional

Hydraulic systemDrive cylinders oil−tight

Switch cylinders oil−tight

Lines and threaded unions oil−tight

Control cabinet All operating elements fully functional

Remote control All operating elements fully functional


Maintenance

5��3AP09_002_0308EN

You must monitor the operational status of your machine and lubri�cate it as required.

Assembly Checking Criterion

General All lubrication points lubricate as required

Switching shaft bearings and seal

Transfer tube Bearings and seal on the pressureconnection

no cement−coloured oil and greasemixture or slurry cement may escapefrom the bearings

Hopper Mixer shaft bearings and sealfrom the bearings

Instruments Monitor all in the normal range

You should carry out the following service operations and checksafter every job.

Assembly Activities and checks Criterion

GeneralCleaning

GeneralAll lubrication points sufficient lubrication

Water box Drain off water

Transfer tubeCheck inner wall and wear ring no mechanical wear

Transfer tubeCheck sealing gap gap < 1�mm

Delivery line Coupling and seal ring on pressurepipe grease

5.1.3 When pumping

5.1.4 After every job

Maintenance

5��4 AP09_001_0902EN

The maintenance tasks �as required" must be carried out if faults arediscovered during the daily checks. Other maintenance work is re�quired at regular intervals. The maintenance cards describe all themaintenance tasks which are within your means to carry out. You canfind these further on in this chapter. The maintenance tasks havebeen listed in the tables according to their time intervals.

You must carry out the work described below if you determine that itis necessary in the course of your daily checks.

Assembly Activity / Maintenance card

Replace the fluid filter

Hydraulic system Replace hydraulic hoses

Tighten / change flared screwed joints

Core pumpTighten bolts on the spacer flange

Core pumpReplace delivery pistons

Measure the wall thickness

Adjust the transfer tube

Transfer tubeReplace the spectacle wear plate

Transfer tubeTighten the clamping bolts on the switch lever

Replace switching shaft bearings and seals

Pressure connection − replace bearings and seals

AgitatorReplace bearings and seals

AgitatorFull transmission oil change

Delivery lineCheck wear

Delivery lineCheck coupling to pressure pipe

5.2 Maintenance work

5.2.1 As required

Maintenance

5��5AP09_001_0902EN

Regular maintenance tasks must be carried out in addition to thedaily visual inspections and function checks and servicing oper�ations.

CautionThe maintenance intervals are specified for normal wear. You willhave to shorten the maintenance intervals accordingly if you arepumping very abrasive media.

You must tighten the fastening bolts on the vibrator and clean thecompressor once a week.

The following tasks must also be carried out after 500 operatinghours, but at least once a year. In addition, a subject expert shouldinspect the pump and the delivery line.


Check threaded unions

General Output test

Function test

Full fluid change and clean fluid sump (replace all filters)

Check LEDs on the valves and magnetic switches

Hydraulic systemCheck the agitator cut−out (function check)

Hydraulic systemClean hydraulic fluid radiator and check function

Check temperature sensor

Check hydraulic accumulator, top up and adjust if necessary

Centralizedlubrication system

Check centralized lubrication system

Electrical systemCheck that all magnetic switches are positioned and functioningcorrectly

5.2.2 Regular maintenancetasks

Weekly

Every 500 hoursof operation

Maintenance

5��6 AP09_001_0902EN


Extend and retract all cylinders to the stop (expel water)

Check the condition of the piston rods

Core pump Check the seals on the piston rods

Check the bolts on the spacer flange

Check the delivery pistons

Check for wear, measure wall thickness

Check setting

Transfer tubeCheck tightening torque of the switch lever clamping bolts

Transfer tubeCheck the ball cups for the switch cylinders

Check the switching shaft bearings and seals

Check the pressure connection bearings and seals

AgitatorChange transmission oil

AgitatorCheck mixer shaft bearings

Full oil change in accordance with manuacturer’s Operating Instructions

Compressor Clean air filter (wash out) in accordance with manufacturer’s OperatingInstructions

Water pumpClean intake filter

Water pumpReplace the HW�520 and WP�50 plastic rollers

EngineMaintenance information in accordance with manufacturer’s OperatingInstructions

Maintenance

5��7BP09_020_1108EN

5.3 Residual risks during maintenance, inspection and repair work

See the "Safety regulations" chapter for personal protective equip�ment requirements.

DangerRisk of serious physical injury if personal protective equipment isnot�worn. Always wear your personal protective equipment duringmaintenance, inspection and repair work. Safety helmet and safetyfootwear are a basic requirement. Other personal protective equip�ment is required as listed in the "Safety regulations" chapter.

Maintenance, inspection and repair work must only be carried outby�qualified personnel. "Qualified personnel" means those who havecompleted specialist training for carrying out such work. This trainingqualifies them to carry out the activity concerned.

Adequate workshop equipment is absolutely necessary for carryingout maintenance, inspection and repair work.

If you do not have qualified personnel, suitable workshop equipmentetc. available, you should commission the manufacturer’s After SalesDepartment with the maintenance of your machine.

5.3.1 Personal protectiveequipment

5.3.2 Personnelrequirements

5.3.3 Auxiliary devices

Maintenance

5��8 BP09_020_1108EN

During maintenance, inspection and repair work, there areparticular�risks of an accident, because for certain activities,protective devices must be removed, for example. There followsa�list of residual risks in particular, which may be present duringmaintenance, inspection and repair work.

DangerThere is a risk of falling when working above the ground or floor.You�should therefore always ensure that you are secure by usingsafety harnesses, railings or walkway barriers. Never use machineparts as climbing aids. Keep all handgrips, steps, railings, platformsand ladders free from dirt, snow and ice.

DangerIn the area between the mixer drum and frame, there is a risk ofbeing pulled in, crushed or injured by shearing. Working in this areais only allowed if the mixer drum is secured with the mixer drumholder. Read the operating instructions from the truck mixer manu�facturer for information about this.

DangerRisk of injury through skin contact with functional fluids(e.g.�hydraulic fluid). Avoid contact with functional fluids.Wear your personal protective equipment. Take note of the safetydata sheets produced by the manufacturer of the functional fluids.

DangerRisk of burning from hot functional fluids and hot surfaces.Allow hot functional fluids and hot surfaces to cool first.Wear your personal protective equipment. Cover hot surfaceswith�heat�resistant materials.

5.3.4 Residual risks

Maintenance

5��9BP09_020_1108EN

DangerRisk of injury from pressurised hydraulic fluid. Put the machine outof�service before starting maintenance, inspection and repair work.Depressurise the hydraulic system. Dump pressure from the accu�mulator.

DangerRisk of injury from compressed air. Put the machine out of servicebefore starting maintenance, inspection and repair work.Depressurise the compressed air system.

DangerRisk of injury from whipping hydraulic hoses. Mechanically pre�stressed hydraulic hoses may lash out when loosening the threadedunion. Wear your personal protective equipment. Secure thehydraulic hoses tightly in place when loosening the threaded unions.

DangerRisk of injury from the machine starting unexpectedly. Before startingmaintenance, inspection and repair work, put the machine out ofservice and secure it against unexpected restarting (e.g. removeignition key and put it in your pocket, place a warning plate on thecontrols). If this is not possible, ask someone to stand guard whocan prevent the machine from starting up unexpectedly.

Maintenance

5��10 BP09_022_1309EN

Tightening torques depend on:− bolt grade− thread friction− bolt head bearing area

The values given in the following tables are for guidance. These va�lues should only be used if no other values are specified in the rel�evant chapters of the Operating Instructions or in spare parts sheets.

CautionYou must always use bolts of the same size and property class whenyou have to replace bolts. Bolts with adhesive in the locking threadsand self�locking nuts must always be replaced after removal.

You will find the maximum tightening torques for set screws and nutsin spare parts list.

NoteFor threaded unions, tighten the union nut using a spanner. Whiledoing so, you must use another spanner to hold the threaded con�nection in place.

10400100

Tighten threaded union

5.4 General tighteningtorques

5.4.1 Set screws and nuts

Maintenance

5��11BP09_022_1309EN

Every time the joint has been undone, the union nut must be tigh�tened again securely without excessive force.

Flared screwed jointsExternaldiameter (RAD)/Type

MA [Nm] Externaldiameter (RAD)/Type

MA [Nm]

6 L 20 16 S 1308 L 40 18 L 12010 L 45 20 S 250

12L 55 25 S 400

12S 80 30 S 500

15 L 70 38 S 800

* RAD = pipe external diameter* MA = tightening torque

" Tighten the union nut using a spanner. While doing so, youmust use another spanner to hold the threaded connection inplace.

After each time the joint is undone, the union nut must be tightenedagain securely without excessive force to ensure that the joint istight.

5.4.2 Flared screwed joint,reassembly

5.4.3 Profiled ring joint,reassembly

Maintenance

5��12 BP09_022_1309EN

Below you will find an overview of the most important components inthe WALFORMplus threaded union. The next section describes whatmust be borne in mind during reassembly of WALFORMplusthreaded unions.

BP09_022_1309EN 1

1 2

34

No. 0 Designation

1 Threaded connection2 Union nut3 Pipe4 Seal

5.4.4 WALFORMplusthreaded union

Maintenance

5��13BP09_022_1309EN

For reassembly of the WALFORMplus threaded union, proceed asfollows:

" Check the thread for cleanliness and damage.

" Clean the thread, and if necessary, replace the parts with adamaged thread.

" Each time the connection is loosened, check the gasket fordamage, and replace it if necessary.

" For threaded unions made of rust�proof steel, grease thethread and the reshaped area of the pipes with an adequateamount of EATON�ABF grease.

" Pull the gasket onto the reshaped pipe as far as the stop.

NoteFirmly tighten the union nut again using the same torque as for initialinstallation.

" Tighten the union nut using a spanner. While doing so, youmust use another spanner to hold the threaded connection inplace.

5.4.5 WALFORMplusthreaded union,reassembly

Maintenance

5��14 BP09_022_1309EN

NoteThe tightening torques are guide values, and only apply to optimumconditions. The torques may deviate substantially because of toler�ance influences, pipes fitted under tension and incorrect lubrication.

Tightening torquesWALFORMplus threaded unions

Externaldiameter (RAD)/Type


MA [Nm]

6 L 30 18 L 1108 L 35 22 L 14010 L 40 28 L 21012 L 55 35 L 30015 L 80 42 L 400


Tightening torquesWALFORMplus threaded unions

Externaldiameter (RAD)/Type


MA [Nm]

6 S 35 20 S 1508 S 40 25 S 21010 S 55 30 S 28012 S 70 38 S 41016 S 110


Maintenance

5��15BP09_004_1703EN

This section lists all the functional fluids used in your machine.

CautionNever use hydraulic fluids or lubricants with additives such as mo�lybdenum. Such additives can attack the bearings.

The hydraulic system is filled with:− mineral hydraulic fluid (HLP) or− biologically degradable hydraulic fluid based on a synthetic ester

(HEES) or− non−readily flammable hydraulic fluid (HFC).

(see also http://www.putzmeister.de/deu/Hydraulicfluids.htm)

Please see the machine card to find out what the initial filling was inyour machine.

DangerNever mix hydraulic fluids of different types, i.e. do not mix biologi�cally degradable hydraulic fluids with mineral hydraulic fluids etc.

5.5 Functional fluids

5.5.1 Hydraulic fluid

Maintenance

5��16 BP09_004_1703EN

NotePlease only use a hydraulic fluid complying with the classificationand requirements standards specified in the lubricant recommenda�tion for topping up or a full fluid change.HEES synthetic esters andHFC aqueous solutions from different manufacturers must not bemixed together without prior approval from the manufacturers con�cerned.

When hydraulic fluids of different viscosity grades are mixed, thenew viscosity is determined by the mix ratio. Loss of quality is poss�ible if hydraulic fluids from different manufacturers are mixed. For thisreason, you must always consult the manufacturer before mixingfluids.

When the hydraulic fluid is changed, some 10�−�15% of the old hy�draulic fluid remains in the system (in cylinders, pumps, lines, etc).

Take note of VDMA (German Engineering Federation) changeoverguidelines and manufacturer instructions when carrying out a fluidchange. Please contact the manufacturers concerned if you haveany queries regarding the suitability and miscibility of hydraulicfluids.

Maintenance

5��17BP09_004_1703EN

Level of contaminant 19/16/12 in accordance with ISO�4406 is speci�fied for lubrication and the hydraulic system. You can find the level ofcontaminant of the initial filling from the test report on the machinecard.

We can carry out a lubricant analysis for you should you discoverthat the functioning of your machine is impaired with one of the lu�bricants or hydraulic fluids used. Please consult Putzmeister, Depart�ment APS (After Sales) and request our analysis kit (materialno.257260.004). We will carry out a lubricant analysis to determinethe cause.

Do not store oils and greases in the open air. Weather variations maycause water to be absorbed through the bung hole.

Only ever store the barrels lying on their side and supported ontimber blocks, with the bung hole facing upwards.

Environmental protectionYou must carefully collect all functional fluids, e.g. used oil (includingbiologically degradable oils), filters and auxiliary materials and dis�pose of them separately from other waste.You must keep used oils ofvarious types separate in order to keep disposal costs as low aspossible.

Observe the national and regional regulations applicable to yourarea. Only work with waste disposal companies who are approvedby the responsible authorities.

5.5.2 Level of contaminant

5.5.3 Lubricant analysis

5.5.4 Storage of lubricants

Maintenance

5��18 BP09_016_0708EN

You will find suitable lubricants and hydraulic fluids in the tablesbelow. Putzmeister accepts no liability for the quality of the lubricantsand hydraulic fluids listed or for changes in quality made by thelubricant manufacturer without changing the grade designation.

NotePlease use only Putzmeister hydraulic fluid, material no. 239879002,when you are topping up the hydraulic fluid or carrying out a full fluidchange if your machine was filled with non−readily flammable hy�draulic fluid in the works (HFC as specified in the 7th LuxembourgReport).

Please use only Putzmeister hydraulic fluid, material no. 239693000,when you are topping up the hydraulic fluid or carrying out a full fluidchange if your machine was filled with a synthetic ester in the works.

Putzmeister accepts no liability for damages caused by mixing fluidsfrom different manufacturers.

You must first consult Putzmeister Department APS if you wish to usehydraulic fluids with viscosity grades other than VG46 (e.g. at higherambient temperatures).

The proportion of residual fluid must not be greater than 2% after afluid change from HLP to HEES. This means that a flushing filling withthe full quantity of the new hydraulic fluid must be carried out. Inaddition, for reasons of gasket compatibility, a fluid change mustbe�carried out no later than 6�months after the machine is commis�sioned. It should also be noted, at this point, that all filters mustbe�changed after 50 hours of operation, since deposits may bedissolved and transported to the filters by the new fluid.

5.6 Lubricantrecommendation

Maintenance

5��19BP09_016_0708EN

CautionThe following points must be complied with in order to preventdamage:� You must warm the machine up briefly if you wish to start using it

when the hydraulic fluid temperature is below 0�_C. To do this,engage the power take−off, switch off the concrete pump andallow the machine to idle for a few minutes.

� The machine should not be placed under full load until the tem�perature of the hydraulic fluid (VG46) has risen above 10�_C.

� The ideal temperature for the hydraulic fluid (HLP or HEES, VG46)is between 40�_C and 70�_C.

DangerNever mix hydraulic fluids of different types, i.e. do not mix biologi�cally degradable hydraulic fluids with mineral hydraulic fluids etc.

Maintenance

5��20 BP09_016_0708EN

5.6.1 Oils

Rotor gearboxAgitatorgearbox

Slewing geartransmission

Transfergearbox

Requirementsstandard

DIN 51 517 DIN 51 517 DIN 51 517

Characteristics synthetic mineral mineral see spare partsViscosity grade,NLGI Class

CLP 220 CLP 220 CLP 220

p psheet

Material no. 295246.006 000101.006 000101.006

NoteTruck transmissions, truck engines and independent power units arefilled by the respective manufacturer. Maintenance only in accord�ance with the manufacturer’s specifications.

Maintenance

5��21BP09_016_0708EN

5.6.2 Greases

Greasing(manual)

Centralizedlubrication system

Greasing the pumptube in rotor pumps

Marking inaccordancewith DIN 51 502

K2K−30 K1K−30 �

Requirementsstandard

DIN 51 825 DIN 51 825 �

Characteristics mineral, lithium soap �Viscosity grade,NLGI Class

NLGI Class 2DIN 51818

NLGI Class 1DIN 51818

�

Material no. 360000.009 360001.008 290207.008

NoteWe recommend the following grease, rather than those specified inthe lubricant table, should you wish to fill the centralized lubricationsystem with a low temperature grease in extremely cold conditions:Marking in accordance with DIN�51502: K�E�2G−60, NLGI Class�2

Maintenance

5��22

BP09_017_1703E

N

5.6.3 Hydraulic fluids

Type Mineral fluid Synthetic ester Aqueous solutionsModel HLP HEES HFC

ClassificationDIN 51502ISO 6743/0

RequirementDIN 51524 Part�2 � �ISO 6743 Part 4 � �

VDMA 24318 24568 24317�/�24320Other � � 7th Luxembourg Report

ViscositiesDIN 51519ISO 3448

mm2/s ISO VG 32 46 68 46 46

Use �15_C to +80_C �10_C to +90_C 0_C to +95_C �10_C to +80_C �20_C to +60_C

Particular char�acteristics

� biodegrades quickly non−readily flammable

Initial fillingMaterial no. 490984 000171.007 279845.009 484527 239879.002

Manufacturer �BECHEM HYDROSTAR

HEES�46FUCHS HYDROTHERM

46�MChangeover guidelines

VDMA � 24569 24314

see also http://www.putzmeister.de/deu/Hydraulicfluids.htm

Maintenance

5��23BP09_013_1205EN

Maintenance cards

In this section you will find the maintenance cards necessary for thismachine. The table of contents includes a summary of the mainten�ance cards in numerical order, you will find an alphabetical summaryin the Index of key words under the entry for �Maintenance cards".

Maintenance

5��24 BP09_013_1205EN

00−001Page 1 of 2

Maintenance�card

5��25WK00_001_1109EN

This maintenance card describes visual checks that you mustcarry�out before commencing any maintenance work. You will findthe maintenance intervals in the maintenance summary at the startof�this chapter.

NoteThere are specific risks of an accident associated with maintenance,inspection and repair work.For this reason, read the chapter "Safety�regulations" and thedescription of the "Residual risks during maintenance, inspectionand repair work" at the start of the chapter entitled "Maintenance"(i.e. this chapter).

See also the maintenance cards:Filter changeHoses

No special tools required.

DangerInspect the electrical cables particularly closely and carefully.There�is a danger of flash overs from defective cables, particularlywhen there is high air or ambient humidity. There is a danger of fireand explosion through the formation of sparks when the machine isused in a potentially explosive atmosphere.

00–001 Visual checks

Maintenance�card00−001Page 2 of 2

5��26 WK00_001_1109EN

The general visual inspections listed below should always be carriedout before any maintenance work, and also each time before startingwork with the machine.

" Check the fill levels of the functional fluids.

" Check that all safety equipment is available and in a fullyfunctioning condition.

Should you locate any damage to the electrical system, you musthave the damage rectified immediately by a qualified electrician.

" Check that all electrical connections are secure and free fromcorrosion.

" Check that the electrical cables have no breaks.

" Check the insulation on the electrical cables.

Timely detection and rectification of damage to the hydraulic systemcan prevent lengthy downtimes and high repair costs.

" Check that the displays on the vacuum meter of the suctionfilters are still in the green range. The suction filters must bereplaced if the displays are in the red range.

Maintenance card: Filter change

" Check the contamination indicators on the boom filters.The�filters are in order if the red button remains depressed.The�filter must be replaced if the red button pops out.


" Check the fluid cooler for contamination and deposits.

" Check all hydraulic hose lines for leaks.


" Check all screwed hydraulic screw�couplings for tightnessand�leaks.


General

Electrical system

Hydraulic system

03−002Page 1 of 2

Maintenance�card

5��27WK03_002_1109EN

This maintenance card describes the inspection of machine func�tions. The inspections are carried out with the machine running. Youwill find the service intervals in the maintenance summary at the startof this chapter.


No further maintenance cards required.

The following special tools are required:Pressure gauge and connections for the tapping points shown in thehydraulic circuit diagram

NoteOnly qualified personnel authorized by us may carry out work on thehydraulic system. Notify the Putzmeister After Sales department orthe dealer/agent who looks after you immediately should you findany irregularities.

" Measure the pressures generated by the pumps, using themeasuring equipment specified directly on the pumps, andcompare your results with the values specified in the testreading.

" Check the proper functioning of the pressure−relief valves inthe high pressure circuit and the pressure accumulator.

03–002 Function checks


5��28 WK03_002_1109EN

03−010Page 1 of 4

Maintenance�card

5��29WK03_010_1109EN

This maintenance card describes a full fluid change on the hydraulicsystem and cleaning the fluid sump in the hydraulic fluid reservoir.

NoteThere are specific risks of an accident associated with maintenance,inspection and repair work. For this reason, read the chapter "Safetyregulations" and the description of the "Residual risks during main�tenance, inspection and repair work" at the start of the chapter en�titled "Maintenance" (i.e. this chapter).

See also the maintenance cards:Function checksFilter changeHoses


NoteCleanliness is of the utmost importance in the maintenance of hy�draulic systems. Prevent any type of dirt and contamination fromentering the system. Even small particles of dirt may cause valves tobe scored, pumps to seize and throttle and control bores to becomeblocked.

Hydraulic fluid barrels must stand for some time before the fluid isremoved from them. Do not roll the barrels to the tapping point.Clean bungs and filler lids as well as the area around them beforeopening the hydraulic fluid reservoir.

If possible, you should use a charging set to fill up the hydraulic sys�tem. Never leave the hydraulic fluid reservoir lid open longer thannecessary.

03–010 Changing the hydraulicfluid


5��30 WK03_010_1109EN

The following tasks must be carried out before starting the full fluidchange:

" Switch off the remote control.

" Switch off the pump.

" Switch off the engine/motor.

" Dump the fluid pressure completely.

DangerPressure stored in accumulators must be dumped.

" Secure the machine against unauthorized starting.

" Secure your working area and fix information plates to thelocked controls and setting devices.

10300400

Draining off the fluid

" Open the fluid drain cock on the hydraulic fluid reservoir andlet the hydraulic fluid drain into a suitable container.

Preparation

Full fluid change

03−010Page 3 of 4

Maintenance�card

5��31WK03_010_1109EN


" Open the cleaning port on the side of the hydraulic fluid reser�voir.

" Remove all filter elements.


" Wipe out all the openings with a lint−free cloth. Wipe as far intothe reservoir as possible when doing this.

" Change all filters and refit the filter elements.

" Replace any defective hoses.


" Check the seals on the cleaning port and replace these if theyshow signs of being defective.

" Close the fluid drain cock and the cleaning port again.

" Check all threaded unions and tighten where necessary. Checkall flared screwed joints.

Maintenance card:Hoses

Clean fluid sump


5��32 WK03_010_1109EN

10300500

Filling the reservoir

" Fill the reservoir with new fluid.

NoteOnly fill the reservoir through the sieve in the filler pipe. After bleed�ing and a test run, top up the reservoir up to the �Maximum" mark.Use only the hydraulic fluids specified in the lubricant recommenda�tion.

" Remove the dirt deposits from the hydraulic fluid radiator.

" Check all threaded unions and tighten where necessary. Checkall flared screwed joints.


" Check the electrical connections.

" Carry out all function checks.

Maintenance card: Function checks

" Bleed the hydraulic system.

" Carry out several test runs.

" Refit all the safety equipment, markings and notices you haveremoved.

04−002Page 1 of 4

Maintenance�card

5��33WK04_002_1110EN

This maintenance card describes how to check and replace thehydraulic hoses. You will find the maintenance intervals in the main�tenance summary at the start of this chapter.




The tightening torques can be found in the correspondingSpare�parts list.

NoteCheck all hydraulic hoses (including hose fittings) with the machinerunning.You must replace the hydraulic hoses at the slightest sign of damageor even mere indications of threatened damage.

04–002 Hydraulic hoses

MA


5��34 WK04_002_1110EN


10400800

Check hydraulic hoses

Dark and moist patches on the fitting are external signs of incipientdamage. Check:− the hydraulic hoses for kinks, cracks or a porous surface and− whether the hydraulic hoses have been laid without restrictions.

NoteBeware of strong sunlight, the action of heat and the effects ofchemicals.

Leakinghydraulic hoses

04−002Page 3 of 4

Maintenance�card

5��35WK04_002_1110EN

The procedure for replacing hydraulic hoses is as follows:

" Shut down the machine and secure against unauthorizedstarting.

" Fully dump any (residual) pressure in the hydraulic system.

DangerHydraulic hoses may be mechanically pre−stressed. There is a riskof injury from whipping hoses.

" Take care when undoing the joints.

" Close the connection points with a plug immediately you haveremoved the old hydraulic hoses. No dirt may enter the hy�draulic circuit and the hydraulic circuit must not run empty.

DangerHydraulic hoses should not be more than six years old, including astorage time of two years. Take note of the date of manufacture onthe hydraulic hoses.

" Keep the hydraulic hoses free from dirt.

" Fit the hydraulic hoses to be free from bends or points of ab�rasion.

" Bleed the hydraulic system.

" Carry out a test run and inspect all hydraulic hoses again afterfitting new hydraulic hoses.

Replacinghydraulic hoses


5��36 WK04_002_1110EN

10400100

Tightening flared screwed joint

" Check whether the flared screwed joints are tight.

NoteYou may only tighten leaking flared screwed joints with the permittedtightening torque. Tighten the flared screwed joints until you clearlyfeel an increase in the force required if you do not have a torquewrench available. You must replace these flared screwed joints ifleaking continues.

The tightening torques can be found in the table �Flared screwedjoints" at the start of this chapter.

Flared screwed joints

04−005Page 1 of 2

Maintenance�card

5��37WK04_005_1109EN

This maintenance card describes how to replace the vacuum meterand how to remove the packing piece. You will find the service inter�vals in the maintenance summary at the start of this section.




NoteReplace the vacuum meter if it is mechanically damaged or if thedisplay is incorrect, e.g. there is an indication although the machineis not running.

CautionYou must remove or open the packing piece once you have fitted thenew vacuum meter.

04–005 Vacuum meter


5��38 WK04_005_1109EN

" Unscrew the old vacuum meter from the vacuum filter.

" Screw the new vacuum meter onto the vacuum filter.

10402000

Venting the vacuum meter

" Open the vent by either cutting off the tip of the packing pieceor piercing the rubber stopper, depending on the design.

04−013Seite 1 von 6

Maintenance�card

5��39WK04_013_1109EN

This maintenance card describes how to change the pressure filterelement. You will find the maintenance intervals in the maintenancesummary at the start of this chapter.





NoteCleanliness is of the utmost importance in the maintenance of hy�draulic systems. Prevent any type of dirt and contamination fromentering the system. Even small particles of dirt may cause valves tobe scored, pumps to seize and throttle and control bores to becomeblocked.

Hydraulic fluid barrels must stand for some time before the fluid isremoved from them. Do not roll the barrels to the tapping point.Clean bungs and filler lids as well as the area around them beforeopening.

If possible, you should use a charging set to fill up the hydraulic sys�tem. Never leave the tank lid open longer than necessary.

04–013 Changing the pressure filterelement

MA

Maintenance�card04−013Seite 2 von 6

5��40 WK04_013_1109EN

CautionFilter elements freely available on the market have too low a flowrate. You must, therefore, only ever use original Putzmeister filter el�ements in order to prevent damage to the machine.

You must never attempt to clean filter elements. These must alwaysbe replaced.


The following tasks must be carried out before changing the filter:

" Switch off the hydraulic pumps.

" Switch off the engine/motor.

" Dump the fluid pressure completely.

" Switch off the remote control.

DangerPressure stored in accumulators must be dumped.

" Secure the machine against being started up by unauthorizedpersons � if you have any key�operated switches, remove thekey and disconnect the supply voltage.

" Secure your working area and fix information plates to thelocked controls and setting devices.

Preparation


Maintenance�card

5��41WK04_013_1109EN

Replace the filter element if the red button on the contamination indi�cator pops out again after being pressed in at operating tempera�ture.

WK04_013_1109EN 1

Checking and changing the pressure filter

" Bring the machine up to operating temperature (>�50�°C).

" Set the maximum engine/motor speed.

" Press the red button on the pressure filter.

NoteThe filter element is OK if the red button remains depressed.

The filter element must be replaced if the red button pops out again.

Checking


5��42 WK04_013_1109EN

WK04_013_1109EN 2

1

2

No. 0 Designation

1 Filter element2 Filter housing

CautionThe filtering process causes dirt and contamination particles toaccumulate in the filter housing. You must therefore clean the filterhousing thoroughly before refitting the new filter element, as other�wise the new filter element will rapidly become clogged again.

Changing


Maintenance�card

5��43WK04_013_1109EN

" Undo the filter housing�(2) and remove the filter element�(1).

" Clean the filter housing�(2) thoroughly with a cleaning rag.

" Install a new filter element.

NoteBefore fitting new filter elements, you must check all O�rings andother seals on the filter elements and replace them if damaged.

" Screw the filter housing back on.

NoteCheck the level of the contamination indicator. Always refit the pro�tective lid on the contamination indicator each time this is checked.


5��44 WK04_013_1109EN

04−019Page 1 of 4

Maintenance�card

5��45WK04_019_1709EN

This maintenance card describes how to change the filter element ofthe DEF delivery pump.

NoteThere are specific risks of accident associated with maintenance,inspection and repair work. For this reason, read the chapter�Safety�regulations" and the description of the �Residual�risks duringmaintenance, inspection and repair work" at the start of the chapterentitled �Maintenance" (i.e.�this chapter).



DangerRisk of injury from rotating and hot components.Carrying out maintenance, repair and cleaning operations on the en�gine and exhaust after treatment system is generally only permittedonce the engine has been switched off and allowed to cool down.Use your personal protective equipment.Observe the requirements and recommendations in the enginemanufacturer’s documentation.

04–019 DEF delivery pump filterchange


5��46 WK04_019_1709EN

CautionCorrosion damage and damage to electrical and electronic compo�nents within the engine compartment caused by leaking DEF lines.Regularly check that all DEF lines and line connections are correctlyseated and leaktight.Seal all leakage points (see the �Exhaust after treatment system"section in the �General technical description" chapter).

NoteOnly qualified personnel may replace filter elements.The filter element must be replaced after every 1000 operating hoursor 3 years, whichever is soonest.Refer to the engine manufacturer’s documentation for details aboutmaintenance of the exhaust after treatment system.

Environmental protectionYou must carefully collect the filter element and diesel exhaust fluid(DEF) and dispose of these separately from other waste.

Observe the national and regional regulations applicable to yourarea. Only work with waste disposal companies who are approvedby the relevant authorities.

NoteCleanliness is of the utmost importance in the maintenance of theexhaust after treatment system. Prevent dirt or other contaminationfrom entering the system. Even small particles of dirt may causevalves to become scored, pumps to seize and throttle and controlbores to become blocked.

04−019Page 3 of 4

Maintenance�card

5��47WK04_019_1709EN

WK04_019_1709EN 1

1

2

3

4

2

Pos.0 Designation

1 DEF delivery pump2 Lid3 Compensating device4 Filter element

DEF delivery pump


5��48 WK04_019_1709EN

" Shut down the engine.

" Allow the engine and the exhaust after treatment system tocool down.

" Disconnect the cable connections of the DEF deliverypump�(1) from the electrical connection.

" Place a suitable container under the DEF delivery pump�(1) soyou are able to collect escaping diesel exhaust fluid.

" Unscrew the lid�(2).

" Pull out the filter element�(4) and the compensating device�(3).

" Refit the new filter element�(4) and the compensating de�vice�(3).

" Screw the lid�(2) back on with the appropriate torque.

" Connect the cable connections of the DEF delivery pump�(1) tothe electrical connection.

" Carry out a test run.

06−023Page 1 of 6

Maintenance�card

5��49WK06_023_1109EN

This maintenance card describes how to replace the deliverypistons. You will find the maintenance intervals in the maintenancesummary at the start of this chapter.




NoteYou must rectify damage to the delivery pistons immediately. Putzmeister accepts no warranty claims for damage to the machineresulting from failure properly to observe the maintenance regula�tions.

DangerSecure the working area. Affix warning notices to the blocked controland setting devices.

06–023 Delivery piston replacement


5��50 WK06_023_1109EN

You will have to start and stop the machine a number of times as youreplace the delivery pistons . The operations necessary for this aredescribed below and must be carried out conscientiously.

Proceed as follows to shut down the machine:

" Set the output to zero.

" Ensure that the Reverse pumping toggle switch on the controlcabinet is set to forwards pumping.

" Stop the engine.

" Check the high−pressure gauge and wait until the fluid pres�sure in the hydraulic system has declined.

" Open the accumulator dump cock on machines with an accu�mulator.

" Close the accumulator dump cock as soon as you can see onthe pressure gauge that the fluid pressure in the accumulatorhas declined.

DangerDump the accumulator pressure completely on machines with accu�mulators.

The procedure for starting up the machine is as follows:

" Set the throttle to one−third.

" Start up the engine.

" Wait until the engine has reached a steady engine speed.

CautionDo not switch the pump on until you are called upon to do so. Youshould also start up the pump quite slowly each time, checking thatthe piston travel direction is correct.

Shutting downthe machine

Starting upthe machine

06−023Page 3 of 6

Maintenance�card

5��51WK06_023_1109EN

Pistons are replaced from the water box.

DangerAlways shut the machine down before you reach into the water box.

10600301

1 2 3 2 4

5

1 Piston rod flange2 Fastening bolts3 Securing wire4 Delivery piston5 Spacer flange

" Shut the machine down.

" Drain the water from the water box and remove the water boxcover.

" Start the machine up.

" Switch the machine on and allow the hydraulic piston of thedelivery piston to be removed to travel slowly to its endposition.

" Switch the pump off once the transfer tube has switched over.� The spacer flange will now be visible in the water box.


Piston replacement


5��52 WK06_023_1109EN

10600701

1

1 Fastening bolts

" Remove the wire clips from the fastening bolts and remove thebolts from the spacer flange.

" Shift the unbolted delivery piston away from the spacer flange,which is still held fast, with an iron bar or by striking it carefullywith a hammer.

" Remove the spacer flange, and store it in such a way that it isprotected against damage until it is reinstalled.


" Switch the concrete pump on at a very low output.� The piston rod flange approaches the delivery pistonslowly.


" Bolt the delivery piston to the piston rod flange.

Removing a piston

06−023Page 5 of 6

Maintenance�card

5��53WK06_023_1109EN


" Set the toggle switch on the control cabinet to reversepumping.

" Switch the concrete pump on at a very low output.� The delivery piston is withdrawn completely from thedelivery cylinder.


" Undo the bolted connection on the piston rod flange andremove the old delivery piston.

" Thoroughly clean the delivery piston edge at the end of thewater box.

CautionDo not use any hard objects or caustic cleaning agents to clean thedelivery cylinder. These could damage the chrome layer.

A piston is fitted in the reverse order of the operations required toremove a piston as follows.

" Grease the new delivery piston heavily with acid−free grease(eg Vaseline).

" Bolt the new delivery piston to the piston rod flange.

Fitting a piston


5��54 WK06_023_1109EN


" Switch the concrete pump on at a very low output.� The new delivery piston is pushed very slowly into thedelivery cylinder.

" Switch the pump off before the fastening bolts for the deliverypiston disappear into the delivery cylinder.


" Undo two fastening bolts on the delivery piston.


" Set the toggle switch on the control cabinet to reversepumping.

" Switch the concrete pump on at a very low output.� The piston rod flange is drawn back.

" Switch the pump off once the spacer flange fits between thepiston rod flange and the delivery piston.


" Insert the spacer flange and fasten all the bolts.

" Tighten the bolts with the specified tightening torques andsecure them with a stainless steel wire.

NoteReplace the second delivery piston in the same way.

" Fasten the water box cover on the water box and fill the waterbox with water.

" Then carry out a test run.

07−069Page 1 of 6

Maintenance�card

5��55WK07_069_1109EN

This maintenance card describes how to replace the transfer tubebearing. You will find the maintenance intervals in the maintenancesummary at the start of this chapter.





Danger of crushingA pressurized hydraulic system may cause the machine to movesuddenly, which may result in you being seriously injured if you areworking on the machine. To avoid risk, shut the machine down andsecure it against unauthorized or accidental starting.

CautionUse only suitable lifting equipment for lifting components.

NoteWear parts must be replaced in the event of one of the following:� Severe wear is visible� Concrete is seeping out

07–069 Replacing the transfer tubebearing

MA


5��56 WK07_069_1109EN

When maintenance work is carried out, the machine must have beenshut down. The operations necessary for this task are describedbelow and must be carried out conscientiously. Perform all machinefunctions using the remote control.


" Switch off the engine.

" Dump the pressures completely.

DangerDump the accumulator pressure completely in systems with pressureaccumulators.

Proceed as follows to start up the machine:

" If there is a throttle, set it to one third.


" Select a low output.


Shutting downthe machine

Starting upthe machine

07−069Page 3 of 6

Maintenance�card

5��57WK07_069_1109EN

The S transfer tube is mounted in the transfer tube bearing in therear wall of the hopper.


" Disconnect the pump from the delivery line.

" Open the grille on the hopper and secure it.

" Attach suitable lifting gear to the S transfer tube.

" Remove the lubrication lines from the transfer tube bearing.

" Undo the nuts on the pressure flange.

" Remove the pressure flange and withdraw the pressure con�nection and the transfer tube bearing.

WK07_069_1109EN 1

1

2

3 4

No. 0 Designation

1 Hopper2 Pressure connection3 Pressure flange4 Hexagon nuts

" Check the seal rings and O−rings in the transfer tube bearingfor wear and replace as required.

Removing the transfertube bearing


5��58 WK07_069_1109EN

WK07_069_1109EN 2

Bending the grooved ring to make installation easier

CautionThe mounting position for the gasket set in the transfer tube bearingcan be found in the corresponding spare parts sheet.

" Grease the new gasket set.

" Bend the grooved ring to make installation easier.

" Insert the gasket set as shown on the spare parts sheet.

NoteClean the transfer tube bearing before refitting and grease the seals.Check the lubricant bores, in particular, for proper functioning. Thisis done by connecting the lubrication lines and forcing greasethrough the openings.

Replacing the transfertube bearing gasketset

07−069Page 5 of 6

Maintenance�card

5��59WK07_069_1109EN

WK07_069_1109EN 3

NotePay attention to the location of the lubrication openings when fittingthe transfer tube bearing.

" Fit the transfer tube bearing and the pressure connection againand bolt them both in place with the pressure flange.

Fitting the transfertube bearing


5��60 WK07_069_1109EN

07−070Page 1 of 16

Maintenance�card

5��61WK07_070_1109EN

This maintenance card describes how to replace the switching shaftbearing (flanged bearing). You will find the maintenance intervals inthe maintenance summary at the start of this chapter.


See also the maintenance cards:Adjusting the S transfer tube





07–070 Replacing the switchingshaft bearing (flangedbearing)

MA


5��62 WK07_070_1109EN







Shutting down themachine

07−070Page 3 of 16

Maintenance�card

5��63WK07_070_1109EN

The machine may be started up differently depending on the ma�chine model. When you are starting up a truck−mounted concretepump, proceed as follows:

" Unlock the EMERGENCY STOP button and sound the horn.

" Switch the engine on.

CautionDo not switch the pump on until you are called upon to do so.

When you are starting up a stationary concrete pump, proceed asfollows:





Starting up themachine


5��64 WK07_070_1109EN

WK07_070_1109EN 1

1 2 3 4 6 7 8 9 10 11

1213

5

14

No. 0 Designation

1 Pulling bore for ball cup2 Ball cup3 Hydraulic port4 Plunger cylinder5 Retaining plate6 Retaining plate fastening bolts7 Switch lever8 Clamping bolts with nuts9 Disc

10 Switching shaft11 Hexagon nut12 Flanged bearing13 Pulling bore for flanged bearing (two diagonally opposite

each other)14 Fastening bolt for flanged bearing (covered)

Overview

07−070Page 5 of 16

Maintenance�card

5��65WK07_070_1109EN

The switching shaft (10) of the S transfer tube is supported in theflanged bearing (12) in the front wall of the hopper.


" Remove any lubrication lines from the retaining plate�(5) andflanged bearing�(12).

WK07_070_1109EN 2

Unbolting the retaining plate

" Screw the fastening bolts�(6) out of the retaining plate�(5) andremove the retaining plate�(5). (You will have to replace thelock washers on the fastening bolts (6) with new ones on reas�sembly.)

Removing the switch-ing shaft bearing(flanged bearing)


5��66 WK07_070_1109EN


" Place an oil sump pan under the working area.

" Place a container under the bulkhead union as well.

" Unscrew the hydraulic hose that leads to the plunger cylinderfrom the bulkhead union.

" Catch the hydraulic fluid flowing out of the hydraulic line andhydraulic hose.

" Seal the hydraulic line with a plug.

07−070Page 7 of 16

Maintenance�card

5��67WK07_070_1109EN

WK07_070_1109EN 3

31 2 4

No. 0 Designation

1 Plunger cylinder2 Locking plate3 Ball cup4 Pulling bore

NoteYou can press a plunger cylinder�(1) out of the ball cup�(3) from thepiston side as shown. If the ball cup is worn, you can screw a boltinto the pulling bore�(4) for the ball cup and press out the plungercylinder with the ball cup.

" Remove the locking plate�(2).

" Press the piston rod on the plunger cylinder�(1) back.

" Catch the hydraulic fluid flowing out of the hydraulic hose.

" Remove the plunger cylinder�(1) and hydraulic hose.


5��68 WK07_070_1109EN

" If required, remove the hydraulic hose from the plunger cylin�der�(1).

" Remove the second plunger cylinder�(1) in the same way.

" Unscrew the hexagon nut and remove it from the switchingshaft, and remove the washer.

NoteIf the switch lever has a slot, this means that the switch lever is fittedwith clamping bolts, and a pulling bolt is also provided.

WK07_070_1109EN 4

1 2 3

4 5 6

No. 0 Designation

1 Clamping bolts2 Switch lever3 Slot4 Pulling bolt5 Holes for clamping bolts6 Nuts for clamping bolts

07−070Page 9 of 16

Maintenance�card

5��69WK07_070_1109EN

WK07_070_1109EN 5

Unscrew and remove the clamping bolts if the switch lever isslotted

" If available, unscrew and remove the clamping bolts�(1) fromthe switch lever (2).

NoteOne of the holes (5) for the clamping bolts�(1) is also the pulling borefor the switch lever�(2).

" If required, force the switch lever�(2) apart by turning the pul�ling bolt supplied�(4) into the pulling bore.

" Pull the switch lever�(2) from the switching shaft.


5��70 WK07_070_1109EN

WK07_070_1109EN 6

1 2

3

No. 0 Designation

1 Fastening bolt2 Pulling bores (two, diagonally opposite each other)3 Flanged bearing

" Unscrew the fastening bolt�(1) from the flanged bearing (3).


" Press out the flanged bearing�(3) by turning the two pullingbolts supplied into the pulling bores�(2).

" Check the gasket set on the flanged bearing for wear, and re�place the gasket set if required.

07−070Page 11 of 16

Maintenance�card

5��71WK07_070_1109EN

WK07_070_1109EN 7

Removing the retaining ring

" Remove the retaining ring.

WK07_070_1109EN 8

Removing the old grooved ring

" Remove the old gasket set. To do this, you may have to cutopen the rings.

Replacing the gasketset in the flangedbearing


5��72 WK07_070_1109EN

WK07_070_1109EN 9

Inserting the new grooved ring

" Clean the flanged bearing.

" Grease the new gasket set.

CautionFor the mounting position of the grooved ring in the flanged bearing,please refer to the accompanying spare parts sheet.

" Insert the gasket set.

" If there is a friction bearing bush, check it and replace ifnecessary.

" Fit the retaining ring.

07−070Page 13 of 16

Maintenance�card

5��73WK07_070_1109EN

WK07_070_1109EN10

1 2 3 4 5

No. 0 Designation

1 Wear sleeve on the flanged bearing2 Flanged bearing3 Collared washer4 Bore5 Tab

" Bend the tab (5) on the collared washer�(3) downwards.

" Place the collared washer�(3) on the flanged bearing (2) so thatthe tab (5) is located in the bore (4), thereby securing thewasher against rotation.

" Insert the wear sleeve�(1) into the flanged bearing (2).

NoteNote the location of the lubrication bores when fitting the flangedbearing (2).

" Grease the inside of the wear sleeve (1) with �Anti−Seize AS450 Assembly Paste" or an equivalent assembly grease.

" Locate the complete flanged bearing�(2) on the switching shaftand bolt the flanged bearing (2) in place.

Wear sleeve onflanged bearing andcollared washer


5��74 WK07_070_1109EN

WK07_070_1109EN11

1 2 3 5

6

4

7

No. 0 Designation

1 Switch lever2 Switching shaft3 Switching shaft bearing (flanged bearing)4 Groove5 Wear sleeve6 Flattened tooth7 Notch

" Grease the teeth on the switch lever (1) and the switching shaft(2) with �Anti−Seize AS 450 assembly paste" or equivalent as�sembly grease.

" Fit the switch lever�(1) so that the flattened tooth�(6) on theswitching shaft�(2) sits in the notch (7) on the switch lever�(1).

" Fit the switch lever�(1) on the switching shaft�(2), so that theswitch lever�(1) sits in the groove (4) on the wear sleeve�(5).

Mounting the switchlever

07−070Page 15 of 16

Maintenance�card

5��75WK07_070_1109EN

" Fit the washer to the switching shaft and screw the hexagonnut onto the switching shaft.

" Lubricate the flanged bearing using the centralized lubricationsystem / grease gun.

" Insert the plunger cylinder.

NoteThe hydraulic system must be bled once assembly is complete if youhave removed the hydraulic hoses from the plunger cylinders. Dothis by starting up the pump slowly and switching the S�transfer tubeacross slowly a few times.

" Adjust the S transfer tube so that it switches correctly.



5��76 WK07_070_1109EN

07−071Page 1 of 14

Maintenance�card

5��77WK07_071_1109EN

This maintenance card describes how to replace the spectacle wearplate. You will find the maintenance intervals in the maintenancesummary at the start of this chapter.


See also the maintenance cards:Replacing the transfer tube bearingReplacing the switching shaft bearing (flanged bearing)Replacing the thrust ring and wear ringAdjusting the S transfer tube

You should request the special fitting instructions from us if you havea spectacle wear plate made from a special material (e.g. hardmetal, hard cast iron, ceramics).



07–071 Replace the spectacle wearplate

MA


5��78 WK07_071_1109EN




07−071Page 3 of 14

Maintenance�card

5��79WK07_071_1109EN


















5��80 WK07_071_1109EN

WK07_071_1109EN 1

1 2 3 4 5 1

66 6

No. 0 Designation

1 Plunger cylinder2 Switch lever3 Clamping bolts with nuts4 Switching shaft5 Hexagon nut6 Fastening bolts for spectacle wear plate

Overview

07−071Page 5 of 14

Maintenance�card

5��81WK07_071_1109EN

The following describes how to remove the spectacle wear plate.


" Undo the hexagon nut�(5) from the switching shaft�(4), removethe plunger cylinder�(1) and undo the clamping bolts�(3) on theswitch lever�(2).

Maintenance card: Replacing the switching shaft bearing

(flanged bearing)

WK07_071_1109EN 2

Pushing the S transfer tube to one side

NoteIf there is not enough space available for assembly, you can pull thepressure connection towards the back.

" Push the S transfer tube away from the spectacle wear plate.

" Undo the eight�fastening bolts (6) for the spectacle wear plate.

" Remove the spectacle wear plate from the hopper.

Removing the spec-tacle wear plate


5��82 WK07_071_1109EN

WK07_071_1109EN 3

2 3 4 51

1

2

No. 0 Designation

1 Transition liner2 Intermediate ring3 Screw plug4 Lubrication nipples5 Grease gun

Replacing the inter-mediate rings

07−071Page 7 of 14

Maintenance�card

5��83WK07_071_1109EN

" Using a plastic−faced hammer, strike the old intermediatering�(2) several times to remove any grout residue that couldblock the intermediate ring�(2) when it is being removed.

" Replace the screw plug�(3) on the underside of the transitionliner�(1) using the lubrication nipple�(4) from the accessories.

" Connect a grease gun�(5) to the lubrication nipple�(4).

" Keep pumping in grease until the intermediate ring�(2) ispressed out.

WK07_071_1109EN 4

Leave the bore open

" Remove the lubrication nipple�(4) again.� This will prevent an air cushion from being formed when thenew intermediate ring�(2) is inserted, allowing you to insert theintermediate ring�(2) more easily.

" Clean the surface thoroughly. Remove all concrete and groutresidue.


5��84 WK07_071_1109EN

WK07_071_1109EN 5

1 32

No. 0 Designation

1 Intermediate ring2 O−rings3 Transition liner

" Slide in two O−rings�(2) over the mounting surface of the newintermediate ring�(1).

" Grease the mounting surface of the new intermediate ring�(1).

" Insert the new intermediate ring�(1) into the transition liner�(3).

07−071Page 9 of 14

Maintenance�card

5��85WK07_071_1109EN

" Using a plastic−faced hammer, tap the intermediate ring�(1)fully into the transition liner�(3).

" Replace the second intermediate ring�(1) in the same way.

WK07_071_1109EN 6

Fitting the O−ring

" Insert one O−ring (2) into the recess at the front of the inter�mediate ring�(1).

The following describes how to insert the spectacle wear plate.

" Fit the new spectacle wear plate.

Fitting the spectaclewear plate


5��86 WK07_071_1109EN

ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ

WK07_071_1109EN 7

1

3

4

2

1

5 6 7

No. 0 Designation

1 Fastening bolts on the left and right2 Spectacle wear plate3 Fastening bolts at the top and bottom4 Intermediate ring5 O−ring6 Hopper wall7 Clearance

07−071Page 11 of 14

Maintenance�card

5��87WK07_071_1109EN

CautionThe spectacle wear plate�(2) only touches the O−rings�(5) in the in�termediate rings�(4). There is a small gap (7) between the spectaclewear plate�(2) and hopper wall (6). For this reason, only tighten thefastening bolts�(1) on the left and right finger−tight at first, becauseotherwise the spectacle wear plate�(2) will be distorted.

" Fit the new spectacle wear plate�(2).

" Using the fastening bolts on the left and right�(1), screw on thenew spectacle wear plate�(2) finger−tight.

NoteIf you have a ceramic spectacle wear plate�(2), please contact ourAfter Sales department to enquire about the tightening torques.

" Using the fastening bolts at the top and bottom (3), screw onthe spectacle wear plate�(2) to the appropriate tighteningtorque.

CautionTake care to ensure that the spectacle wear plate�(2) does not be�come distorted.

" Using the fastening bolts on the left and right (1), screw on thespectacle wear plate�(2) to the appropriate tightening torque.


5��88 WK07_071_1109EN

WK07_071_1109EN 8

Close the fitting bore

CautionThe fitting bores must be closed to prevent any dirt penetration.

To seal the pulling bores, only use the screw plugs, and not the lu�brication nipples. Otherwise, there is a risk that you will accidentallylubricate these lubrication nipples as well while lubricating the ma�chine. Over time, this would push out the intermediate rings, and thespectacle wear plate would be distorted.

" After inserting the new intermediate rings and spectacle wearplate, seal the pulling bores again using the screw plugs.

07−071Page 13 of 14

Maintenance�card

5��89WK07_071_1109EN

" Replace the thrust ring and wear ring.

Maintenance card: Replacing the thrust ring and wear ring

" Fit the transfer tube bearing.

Maintenance card: Replacing the transfer tube bearing

" Insert the plunger cylinder.


(flanged bearing)




5��90 WK07_071_1109EN

07−072Page 1 of 8

Maintenance�card

5��91WK07_072_1109EN

This maintenance card describes how to replace the S transfer tube.You will find the maintenance intervals in the maintenance summaryat the start of this chapter.


See also the maintenance cards:Replacing the transfer tube bearingReplacing the switching shaft bearing (flanged bearing)Replacing the S transfer tube wear sleeveReplacing the thrust ring and wear ringAdjusting the S transfer tubeMeasuring the wall thicknessMeasuring the wall thickness of the double−layer pipe



07–072 Replacing theS transfer tube

MA


5��92 WK07_072_1109EN




We recommend that the switch lever also be replaced when the Stransfer tube is replaced. Practical experience has shown that thetoothing on the switching shaft and that on the switch lever wear to�gether as a result of the forces generated during switchover. Dam�age may be caused by an imprecise fit if only one component is re�placed.


(flanged bearing)

07−072Page 3 of 8

Maintenance�card

5��93WK07_072_1109EN


















5��94 WK07_072_1109EN

WK07_072_1109EN 1

1 2

No. 0 Designation

1 S transfer tube with bolted switching shaft2 S transfer tube with welded switching shaft

NoteWhichever variant of S transfer tube is fitted, the recommended pro�cedure for dismantling is as described below. The S transfer tubewith bolted switching shaft may also be dismantled and reassembledin the hopper. The tube is then dismantled as described in the �Stransfer tube with bolted switching shaft" maintenance card.

You should also consult the �Divided hopper" maintenance card ifyour machine has a divided hopper.

S transfer tube vari-ants

07−072Page 5 of 8

Maintenance�card

5��95WK07_072_1109EN

Replace the S transfer tube if the wall thickness has fallen below theminimum.

Maintenance card: Measuring the wall thickness

Maintenance card: Measuring the wall thickness of the double−

layer pipe



" Remove the transfer tube bearing.


" Remove the switching shaft bearing (flanged bearing).


(flanged bearing)

WK07_072_1109EN 2

Removing the mixer shaft

" Remove the mixer shaft.

Removing the Stransfer tube


5��96 WK07_072_1109EN

WK07_072_1109EN 3

Lifting out the S transfer tube

" Unbolt the scratch bar from the bottom of the S transfer tube.

" Push the S transfer tube forwards until the transfer tube outletis free.

" Lift the S transfer tube outlet opening first upwards and out.

NoteIf just the wear sleeve is heavily worn, you can also replace just thewear sleeve and then refit the S transfer tube.

Maintenance card: Replacing the wear sleeve on the S transfer

tube

" Fit the new S transfer tube. To do this, proceed in the reverseorder to removal.

07−072Page 7 of 8

Maintenance�card

5��97WK07_072_1109EN

" Fit a new thrust ring and a new wear ring.

Maintenance card: Replacing the thrust ring and wear ring

" Fit the switching shaft bearing (flanged bearing).


(flanged bearing)






5��98 WK07_072_1109EN

07−073Page 1 of 8

Maintenance�card

5��99WK07_073_1109EN

This maintenance card describes how to replace the wear sleeve onthe S transfer tube. You will find the maintenance intervals in themaintenance summary at the start of this chapter.


See also the maintenance cards:Replacing the transfer tube bearingReplacing the switching shaft bearing (flanged bearing)



07–073 Replacing theS transfer tube wear sleeve

MA


5��100 WK07_073_1109EN




07−073Page 3 of 8

Maintenance�card

5��101WK07_073_1109EN


















5��102 WK07_073_1109EN

If just the wear sleeve is heavily worn, you can replace it without hav�ing to replace the S transfer tube. You do not have to remove the Stransfer tube to do this.




" Loosen the hexagon nut on the switching shaft and the clamp�ing bolts on the switch lever.


(flanged bearing)

DangerThere is a risk of burning during heating and fitting of the new wearsleeve. Use suitable protective equipment.

Removing the wearsleeve

07−073Page 5 of 8

Maintenance�card

5��103WK07_073_1109EN

WK07_073_1109EN 11 2 3

No. 0 Designation

1 Welds2 Tube outlet3 Wear sleeve

If the S transfer tube has been fitted, proceed as follows:

" Weld a metal pin onto the wear sleeve.

CautionWhen cutting open the welds, take care not to damage the S transfertube.

" Carefully cut open the welds (1) on the front face between theS transfer tube outlet�(2) and wear sleeve�(3) using an anglegrinder.

" Heat up the wear sleeve�(3) evenly to approx. 140�°C.

Removal when the Stransfer tube is fitted


5��104 WK07_073_1109EN

" Using a hammer, strike the metal pin to release the wearsleeve.

" Remove the wear sleeve�(3).

If the S transfer tube has been removed, proceed as follows:

CautionWhen cutting open the welds and wear sleeve, take care not to dam�age the S transfer tube.

" Carefully cut open the welds (1) on the front face between theS transfer tube outlet�(2) and wear sleeve�(3) using an anglegrinder.

" Heat up the wear sleeve�(3) evenly to approx. 140�°C.

" Cut open the wear sleeve carefully using an angle grinder.

" Remove the wear sleeve�(3).

Removal when the Stransfer tube has beenremoved

07−073Page 7 of 8

Maintenance�card

5��105WK07_073_1109EN

WK07_073_1109EN 2

1 2

No. 0 Designation

1 Wear sleeve2 Tube outlet

NoteThe wear sleeve�(1) is chrome−plated, and must not therefore beheated unevenly or too intensively.

" Heat up the new wear sleeve�(1) evenly to approx. 140�_C.

" Place the heated wear sleeve�(1) over the tube outlet (2) andallow the wear sleeve�(1) to cool.

" On the front face, evenly position four welds between the wearsleeve�(1) and tube outlet�(2).

" Grind the four welds.

Fitting a wear sleeve


5��106 WK07_073_1109EN



" Tighten the hexagon nut on the switching shaft and the clamp�ing bolts on the switch lever.


(flanged bearing)

07−074Page 1 of 6

Maintenance�card

5��107WK07_074_1109EN

This maintenance card describes how to replace the thrust ring andwear ring on the S transfer tube. You will find the maintenance inter�vals in the maintenance summary at the start of this chapter.


See also the maintenance cards:Replacing the transfer tube bearingReplacing the switching shaft bearing (flanged bearing)Replacing the spectacle wear plateAdjusting the S transfer tube



07–074 Replacing the thrust ringand wear ring

MA


5��108 WK07_074_1109EN




07−074Page 3 of 6

Maintenance�card

5��109WK07_074_1109EN


















5��110 WK07_074_1109EN

To remove the thrust ring and wear ring, proceed as follows:




" Loosen the hexagon nut on the switching shaft and the clamp�ing bolts on the switch lever.


(flanged bearing)

" Inspect the spectacle wear plate and replace it if required.

Maintenance card: Replacing the spectacle wear plate

Removing the thrustring and wear ring

07−074Page 5 of 6

Maintenance�card

5��111WK07_074_1109EN

WK07_074_1109EN 1

1 2

No. 0 Designation

1 Thrust ring2 Wear ring

" Remove the old wear ring (2) and the old thrust ring (1).

To fit the thrust ring and wear ring, proceed as follows:

" Clean the thrust ring seat (1) thoroughly. Dirt and concrete resi�due must be removed from the seat.

" Fit the new thrust ring (1) and new wear ring (2) into the Stransfer tube.





Fitting the thrust ringand wear ring


5��112 WK07_074_1109EN

07−075Page 1 of 14

Maintenance�card

5��113WK07_075_1109EN

This maintenance card describes how to adjust the S transfer tube.This includes:− prestressing the S transfer tube and− adjusting the switching overlap between the wear ring and spec�

tacle wear plate on the S transfer tube.


See also the maintenance cards:Replacing the switching shaft bearing (flanged bearing)



07–075 Adjusting theS transfer tube

MA


5��114 WK07_075_1109EN




07−075Page 3 of 14

Maintenance�card

5��115WK07_075_1109EN

You will have to shut down and restart the machine a number oftimes. The operations necessary for this task are described belowand must be carried out conscientiously. Perform all machine func�tions using the remote control.

















5��116 WK07_075_1109EN

First, prestress the S transfer tube.


WK07_075_1109EN 11 2 3 4

5 6 7

9

8

No. 0 Designation

1 Spectacle wear plate2 Wear ring3 S transfer tube4 Thrust ring5 Gap6 Hexagon nut7 Retaining plate8 Switch lever9 Clamping bolts

NoteMake sure that the thrust ring (4) is not damaged when it is pressedin.

" Unscrew the clamping bolts�(9) from the switch lever�(8).

Prestressing the Stransfer tube

07−075Page 5 of 14

Maintenance�card

5��117WK07_075_1109EN

" Tighten the hexagon nut�(6) on the switching shaft so that thewear ring�(2) lies flat against the spectacle wear plate�(1).

NoteA gap (5) must be maintained between the S transfer tube�(3) andwear ring�(2) so that the S transfer tube�(3) switches correctly.

" Check that the wear ring (2) makes contact with the spectaclewear plate (1) on all sides.

" Slowly tighten the hexagon nut�(6) by half a turn.� The thrust ring (4) is then compressed by 1.5�mm.� The gap (5) between the S transfer tube�(3) and wearring�(2) is set.

" Ensure that one surface on the hexagon nut�(6) is horizontal atthe top so that the retaining plate�(7) can be refitted.

" Fit the retaining plate�(7).

NoteUse only new nuts for the clamping bolts (9).

" Insert the clamping bolts (9) into the switch lever (8) and fitnew nuts.

" Tighten the clamping bolts�(9) to the required torque.

" Further assembly is carried out in the reverse sequence to dis�assembly.


(flanged bearing)

" Check that all covers and other safety equipment have beenrefitted and are fully functional.


5��118 WK07_075_1109EN

The switching overlap is set to the optimum if the wear ring is centralto the relevant hole in the spectacle wear plate for both switch posi�tions of the S transfer tube. In other words, the swing angle of the Stransfer tube must not be either too great or too small.

WK07_075_1109EN 2

1 2

3

No. 0 Designation

1 Swing angle too great2 Swing angle too small3 Optimum swing angle

The left−hand switching overlap is corrected by replacing the pack�ing washer behind the ball cup on the right−hand plunger cylinderwith a thicker or thinner one as required. The right−hand switchingoverlap is corrected on the left in the same way.

Setting the switchingoverlap

Spectacle wear platewith wear ring

07−075Page 7 of 14

Maintenance�card

5��119WK07_075_1109EN

WK07_075_1109EN 3

1 2 3

No. 0 Designation

1 Plunger cylinder2 Ball cup3 Packing washer


WK07_075_1109EN 4

Plunger cylinder extended

" Allow one plunger cylinder to retract completely.



5��120 WK07_075_1109EN

WK07_075_1109EN 5

1

No. 0 Designation

1 Marking the spectacle wear plate

" Use a felt tip pen or oil chalk to mark the position of the wearring on the spectacle wear plate.


" Allow the other plunger cylinder to retract.


" Determine to which side and by how many millimetres thecircle you have drawn is offset against the circle of the spec�tacle wear plate.

07−075Page 9 of 14

Maintenance�card

5��121WK07_075_1109EN

WK07_075_1109EN 6

1 2

3

No. 0 Designation

1 Packing washer too thin2 Packing washer too thick3 Optimum packing washer

To decrease the swing angle of the S�transfer tube by 4�mm, thefitted packing washer must be replaced by one which is 2�mmthicker.To increase the swing angle of the S�transfer tube by 4�mm, the fittedpacking washer must be replaced by one which is 2�mm thinner.

Spectacle wear platewith sample markings


5��122 WK07_075_1109EN

WK07_075_1109EN 7

1 2

No. 0 Designation

1 Plunger cylinder2 Locking plate

" Remove the locking plate�(2) of the extended plunger cylin�der�(1).

10300800

Removing the plunger cylinders

NoteThe plunger cylinders can be pushed back as illustrated. It is, how�ever, also possible to screw a bolt into the jacking bores for the ballcups and to push the plunger cylinders out with the ball cups.

07−075Page 11 of 14

Maintenance�card

5��123WK07_075_1109EN

" Force the piston of the extended plunger cylinder back a littleand remove the plunger cylinder with the hydraulic hoses.

WK07_075_1109EN 8

1 2

No. 0 Designation

1 Ball cup2 Packing washer

" Remove the hexagon ball cup (1) along with the packingwasher (2).

CautionNo packing washers (2) may be inserted in the switch lever, as other�wise the plunger cylinder can run over the edge of the ball cup (1)and break it.

" As required, fit a thicker or thinner packing washer (2) with theball cup (1).

" Fit the plunger cylinder and locking plate.



5��124 WK07_075_1109EN

" Allow the S�transfer tube to switch over a few times. StoppenSie, wenn die S−Rohrweiche auf der noch nicht markierten Bril�lenplattenseite steht.


" Check the switching overlap of the other side of the spectaclewear plate and correct accordingly.

The two plunger cylinders must extend to the same extent on ma�chines with fully hydraulic control (VHS) and active signal tapping inthe plunger cylinders.

20300703

Plunger cylinder extended

" First set a switching overlap of the wear ring and the spectaclewear plate.

" Allow the plunger cylinder (1) to extend to its end position.


" Measure how far the plunger cylinder has extended. (Measure�ment E1)


Switching overlap onVHS control

07−075Page 13 of 14

Maintenance�card

5��125WK07_075_1109EN

" Allow the plunger cylinder (2) to extend to its end position.


" Measure how far the plunger cylinder has extended. (Measure�ment E2)

" Compare the two measurements.

The two measurements E1 and E2 should be identical. You will haveto change the packing washers as described below if the twomeasurements are not equal:

" Swap the packing washer on the plunger cylinder with thegreater measurement for a washer (E1−E2):2 thinner.

" Swap the packing washer on the plunger cylinder with thesmaller measurement for a washer (E1−E2):2 thicker.

NoteThis setting must be checked after a running−in period of approxi�mately 100 operating hours.


5��126 WK07_075_1109EN


Maintenance�card

5��127WK07_078_1304EN

This maintenance card describes how to fit the resolver on theswitching shaft.

NoteThere are specific risks of accidents associated with maintenance,inspection and repair work. For this reason, read the chapter�Safety�regulations" and the description of the �Residual�risks duringmaintenance, inspection and repair work" at the start of the chapterentitled �Maintenance" (i.e.�this chapter).



NoteThe resolver measures the position of the S transfer tube and con�trols the graphic display of the switchover procedure in the ErgonicGraphic Display (EGD).

If you want to carry out service and maintenance work on the Stransfer tube, you must remove the resolver from the switching shaftand refit it as described in the following.

07–078 Resolver on the switchingshaft


5��128 WK07_078_1304EN

WK07_078_1304EN 1

2

1

1

2

345

No. 0 Designation

1 Connecting cable2 Resolver3 Magnetic sensor4 Switch lever5 Switch cylinders

" Fit the resolver�(2) as shown in the graphic.� The resolver is located in its electrical middle position.

" Maintain the reacting distance �a" (a = 8 +/− 4�mm).

08−007Page 1 of 2

Maintenance�card

5��129WK08_007_1109EN

This maintenance card describes how to lubricate the machine. Themachine is lubricated through a centralized lubrication nipple strip.The lower bearings of the switch cylinders must also be lubricated.All lubrication nipples must be lubricated once a day.



The following special tools are required:Grease gun

NoteUse only those lubricants listed in the lubricant recommendationtable.

08–007 Lubrication


5��130 WK08_007_1109EN

1

3

2

WK08_007_1109EN 1

1 Plate indicating the lubrication intervals2 Centralized lubrication nipple strip3 Lubrication nipple for the lower bearings on the switch cylinder

" Lubricate each lubrication nipple with a grease gun until cleangrease exits from the lubrication point.

NoteThe lubrication interval is specified for normal operation. More fre�quent lubrication may be necessary under extreme conditions.

10−007Page 1 of 6

Maintenance�card

5��131WK10_007_1109EN

This maintenance card describes how to measure the wall thicknessof delivery lines. You will find the maintenance intervals in the main�tenance summary at the start of this chapter.



The following special tools are required:Wall thickness measuring device


10–007 Measuring the wall thick-ness (Machines withS transfer tube)

MA


5��132 WK10_007_1109EN

NoteDelivery lines are subject to constant wear. Measurement of the wallthickness is particularly important before starting on large jobs.You will obtain reliable results for your measurements if you carry outthe test with the measuring device recommended by Putzmeister.

Danger of explosionThe delivery line can burst once it reaches a high delivery pressure ifthe wall thickness of the delivery line has decreased below the mini�mum required, particularly if a blockage has built up.

10−007Page 3 of 6

Maintenance�card

5��133WK10_007_1109EN

CautionOnly tap the delivery line with a piece of hardwood (hammer handle).Otherwise, dents may be created and these will lead to more rapidwear. In addition, the hardened lining of high wear resisting pipesmay flake off the inside of the pipe. The pipe can burst at points thathave suffered heavy wear.

11000101

Tapping the delivery line with a hammer handle

Uniform wear can be achieved by regularly rotating the straight de�livery pipes through 120°.The minimum wall thickness for straight pipes is shown in the graphbelow.

Uniform wear can be achieved by regularly rotating the bendsthrough 180°. The wear on the external radius of a bend is greaterthan that on the internal radius or on straight pipes. You should,therefore, take special care when measuring the wall thickness of theexternal radius of a bend.The minimum wall thickness for bends is shown in the graph below.

11000200

Rotate delivery pipes and bends regularly

Straight pipes

Bends


5��134 WK10_007_1109EN

The minimum wall thickness for the S transfer tube depends on themaximum possible operating pressure. Furthermore, the fact that theS transfer tube is subject to greater stress at the point at which thetorque is applied (switching shaft − S transfer tube) must be takeninto consideration.

WK10_007_1109EN 1

X = Area of heavy loading

Operating pressure up to130 bar

Guide value for wall thick-ness

Area�A 8�−�10�mm

Area�B 6�−�8�mm

NoteWe should draw your attention to the fact that the S transfer tube issubject to varying loading as a result of the dynamic loading duringpumping. There is no general method for calculating the minimumwall thickness for this loading, which depends on the individual cir�cumstances, and so the S transfer tube can also burst at an operat�ing pressure which is assumed still to be permissible.

You should also note that the operating pressure can rise to themaximum pressure in the event of a blockage, and in this case thewall thickness may no longer be adequate.

If the operating pressure is higher than 130�bar, you must askPutzmeister what the minimum wall thickness is.

S transfer tube

10−007Page 5 of 6

Maintenance�card

5��135WK10_007_1109EN

Follow the Operating Instructions supplied with the measuring de�vice when carrying out measurements. Do not measure the wallthickness of the delivery line at just one point, but around the entirecircumference of the delivery pipes.The minimum wall thickness is shown in the graph below.

CautionPipes and bends must be replaced as soon as the wall thicknesshas declined to the value for the minimum wall thickness.Putzmeister accepts no liability if the wall thickness is less than theminimum wall thickness.

NoteAs a rule it is possible to continue pumping with an operating pres�sure lower than that shown in the graph.

We should, however, draw your attention to the fact that the deliveryline is subject to varying loading as a result of the dynamic loadingduring pumping. There is no general method for calculating the mini�mum wall thickness for this loading, which depends on the individualcircumstances, and so the delivery line can also burst at an operat�ing pressure which is assumed still to be permissible.

Furthermore, the operating pressure can rise to 85 bar in the event ofblockages, meaning that the wall thickness will no longer be ad�equate and the delivery line will burst.

Measuring


5��136 WK10_007_1109EN

Minimum wall thickness as a function of operating pressure

1

2

1 High pressure2 Maximum delivery pressure

Graph

10−044Page 1 of 2

Maintenance�card

5��137WK10_044_1109EN

This maintenance card describes how to measure the wall thicknessof two−layer delivery lines.


See also the maintenance cards:Measuring the wall thickness

The following special tools are required:Wall thickness measuring device, material no. 454460

NoteObserve all safety instructions in the machine−specific OperatingInstructions and in the Safety manual.

Danger of explosionYou must not open or tap delivery lines while these are pressurized.Concrete exiting under pressure can cause injury. The concrete columnmust be depressurized by reverse pumping before the delivery lineis opened. Never work bending directly over the coupling.

10–044 Measuring the wall thick-ness of two–layer pipes


5��138 WK10_044_1109EN

Inspect two−layer delivery pipes and delivery line elbows(DN�125,�max. concrete pressure 85 bar) as follows:

" Visual inspection for cracks. Replace in case of crackformation.

" Measure the wall thickness at the measuring points P1 and P 2.Replace if the wall thickness has fallen below the minimumrequired (see table).

Type Minimum (mm)

No. DN 125up to 85 bar

P1 P2

Twin Pipe Twin Cast

1.1Delivery line elbow

7.1 + 3.6 4.1 3.6

1.2Delivery line elbow

7.0 + 2.0 7.0 3.0

2.1 2.5 + 2.0 2.5 3.3

2.2Delivery pipe

2.5 + 2.0 2.5 4.9

2.3Delivery pipe

5.6 + 3.0 3.7 3.7

2.4 5.6 + 3.0 3.7 3.1

1.1 – 1.2Delivery line elbowMeasuring pointsP1/P2Minimum (see�table)

2.1 – 2.4Delivery pipeMeasuring pointsP1/P2Minimum (see�table)

Extract from Esser Service Manual – EM 070190, see Technical Appendix

Inspecting two–layerdelivery pipes anddelivery line elbows


6 — I

6 Index of key words

In this section you will find the most important key words with thenumber of the page on which you will find the key word as a headingin the left margin. This Index of key words is listed alphabetically bythe main concepts. These are subdivided into associated sub−con�cepts, marked with a dash.


6 — II


i

AAccumulator dump valve, Emergency

operation, 4��6

Agitator, Emergency operation, 4��3

Agitator emergency operation, 4��3

Agitator gearbox, Transmission oil,5��20

Agitator safety cutout� Acknowledge, 3��11� Checking the safety function, 3��7� Description of the functions, 3��8� Function check, 3��9� Unexpected restart, 3��11

CCentralized lubrication system� Grease, 5��21� Low temperature grease, 5��21

Components� Electrical components, 2��8� Safety�relevant components, 2��5

Control devices� Accumulator dump valve, 4��6� Agitator valve, 4��3� Drive cylinder emergency operation,4��1

� Emergency operation � delivery cylin�der, 4��6

� Emergency operation � transfer tube,4��1, 4��6

� Pump control system, 4��1, 4��6

Copyright, 1��2

DDelivery cylinder, Emergency opera-

tion, 4��6

Delivery line� Measuring the wall thickness, 5��137� Measuring the wall thickness (Machi�nes with S transfer tube), 5��131

Delivery piston, Piston replacement,5��49

Diesel Exhaust Fluid (DEF) deliverypump filter change, Maintenancecard, 5��45

Disposal, Machine, 2��12

EElectrical components, 2��8

Electrical power, 2��7� Power at the construction site, 2��8

Emergency operation� Agitator, 4��3� Delivery cylinder, 4��6� Drive cylinder, 4��1� Transfer tube, 4��1, 4��6

EMERGENCY STOP function� Checking the safety function, 3��5� Description of the functions, 3��5� Function check, 3��6

Exhaust fumes, 2��11

FFaults, Recovering the machine, 4��5

Filter change, Pressure filter, 5��39

Flanged bearing, Replacing, 5��61

Flared screwed joint, 5��11

Fluid drain cock, 5��29

Fumes� Exhaust, 2��11� Noise, 2��10

Function checks, 5��27

Functional fluids, 2��11, 5��15

GGrille� Checking the safety function, 3��15� Description of the functions, 3��15� Function check, 3��16

HHydraulic fluid� Fluid drain cock, 5��29� Full fluid change, 5��29

Hydraulic hoses, 2��10� Maintenance, 5��33

Hydraulic systems, 2��9

IIcons, 1��3

Intermediate rings on the transitionliner, Replacing, 5��82

LLiability, Exclusion, 2��1

Lubricant analysis, 5��15, 5��17

Lubricant recommendation� Agitator gearbox, 5��20� Engine oil, 5��20� General, 5��18� Greases, 5��21� Hydraulic fluids, 5��22� Low temperature grease, 5��21� Oils, 5��20� Pump tube grease, 5��21� Rotor gearbox, 5��20� Slewing gear transmission, 5��20� Transfer gearbox, 5��20� Transmission oil, 5��20

Lubrication, Grease, 5��21

MMaintenance and special work, 2��2

Maintenance cards� Adjusting the S transfer tube, 5��113� Changing the hydraulic fluid, 5��29� Changing the pressure filter element,5��39

� DEF delivery pump filter change, 5��45� Delivery piston replacement, 5��49� Function checks, 5��27� Hydraulic hoses, 5��33� Lubrication, 5��129� Measuring the wall thickness, 5��137� Measuring the wall thickness (Machi�nes with S transfer tube), 5��131

� Replace the spectacle wear plate,5��77

� Replacing the S transfer tube, 5��91� Replacing the S transfer tube wearsleeve, 5��99

� Replacing the switching shaft bearing(flanged bearing), 5��61

� Replacing the thrust ring and wearring, 5��107

� Replacing the transfer tube bearing,5��55

� Resolver on the switching shaft, 5��127� Vacuum meter, 5��37� Visual checks, 5��25


ii

Measuring the wall thickness, 5��137� Machines with S transfer tube, 5��131

NNoise emissions, 2��10

OOrganizational measures, Plates, 3��1,3��17

PParts with increased maintenance re-

quirements, 3��4

Placing boom, Working on the pla-cing boom, 2��5

Plates, Inspection, 3��17

Power, 2��8

Power at the construction site, 2��8

Profiled ring joint, 5��11

Protective devices, Grille, 3��15

Protective equipment, 2��6

Pump control system, 4��1� Emergency operation, 4��6

Pump tube in rotor pumps, Grease,5��21

RRecovering the machine, 4��5� With on�board equipment, 4��6

Rotor gearbox, Transmission oil, 5��20

Rotor pumps, Pump tube grease,5��21

SS transfer tube� Adjusting, 5��113� Measuring the wall thickness, 5��131� Prestressing, 5��116� Replacing, 5��91� Switching overlap, 5��118

S transfer tube wear sleeve, Repla-cing, 5��99

Safety components, 3��4

Safety equipment, 2��6� Active safety functions, 3��1� Overview, 3��1� Passive safety functions, 3��1� Plates, 3��17� Safety−related parts (SRPs), 3��2� Separating protective devices, 3��13

Safety functions� Active, 3��1� Agitator safety cutout, 3��7� EMERGENCY STOP function, 3��5� Grille, 3��15� Passive, 3��1� Separating protective devices, 3��13

Safety regulations� Basic principle, 2��1� Exclusion of liability, 2��1

Safety–related parts (SRPs), 3��2

Safety-relevant components, 2��5

Separating protective devices, 3��13

Slewing gear transmission, Transmis-sion oil, 5��20

Software, 2��6

Special work, 2��2

Spectacle wear plate, Replacing, 5��77

SRP, 3��2

Switching shaft bearing, Replacing,5��61

Symbols, 1��3

TThrust ring, Replacing, 5��107

Tightening torques� Flared screwed joint, 5��11� General, 5��10� Profiled ring joint, 5��11� Set screws and nuts, 5��10� WALFORMplus threaded union, 5��12

Transfer gearbox, Transmission oil,5��20

Transfer tube, Emergency operation,4��6

Transfer tube bearing, Replacing,5��55

Transfer tube change-over valves,Emergency operation, 4��1

Transition liner, Replacing the inter-mediate rings, 5��82

Transmission oil� Agitator gearbox, 5��20� Rotor gearbox, 5��20� Slewing gear transmission, 5��20� Transfer gearbox, 5��20

Two–layer delivery line elbow, Inspec-tion, 5��138

Two–layer delivery pipe, Inspection,5��138

UUnexpected restart, Agitator safety

cutout, 3��11

VVacuum meter, Venting, 5��37

Visual checks, 5��25

WWALFORMplus threaded union, 5��12

Wear ring, Replacing, 5��107

Welding, 2��4

Documents

Operating Instructions - RAMCRETE