Operating Instructions

for machine operator and maintenance staff

always keep by the machine

Translation of the original Operating Instructions

Stationary
concrete pump BSA 1005 D3B C

Machine no. 210109379

16−04−07

The paper on which this document is printed is 100% chlorine free E Putzmeister Concrete Pumps GmbH 1994
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 de Übersetzung der Originalbetriebsanleitung
bg Ïðåâîä íà îðèãèíàëíî Ðúêîâîäñòâî çà ðàáîòà
cs Pƙeklad 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 Lietoơanas pamcbas tulkojums no oriinlvalodas
nl Vertaling van de oorspronkelijke gebruiksaanwijzing
no Oversettelse av original brukerhåndbok
pl TƂumaczenie oryginalnej instrukcji eksploatacji
pt Tradução das Instruções de funcionamento originais
ro Traducerea instrucƣiunilor de funcƣionare 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 kullanűm kűlavuzunun tercümesi

BP00_030_0911EN
 Tableofcontents

Table of contents
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 Boom pedestal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  1
2.1.4 Arm assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  1
2.1.5 Placing boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  1
2.1.6 Base structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  1
2.1.7 Truck mixer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  2
2.1.8 Delivery line systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  2
2.1.9 Guiding the end hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  2
2.1.10 Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  2
2.1.11 Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  2
2.1.12 Machine operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  2
2.1.13 Hoseman . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  2
2.1.14 Signaller and other auxiliary personnel . . . . . . . . . . . . . . . . . . 2  2
2.1.15 Truck mixer driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  3
2.1.16 Authorized inspector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  3
2.1.17 Subject expert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  3
2.1.18 Qualified personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  3
2.1.19 After Sales Service personnel . . . . . . . . . . . . . . . . . . . . . . . . . . 2  3
2.1.20 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  3
2.1.21 Place of work, working area, danger zone . . . . . . . . . . . . . . . 2  4

2.2 Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 9

2.2.1 Retesting (safety inspection) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  9
2.2.2 Inspection intervals for retesting . . . . . . . . . . . . . . . . . . . . . . . 2  10

2.3 Use contrary to designated use . . . . . . . . . . . . . . . . . . . . . . 2 — 11

2.3.1 Transporting goods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  11
2.3.2 Lifting loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  11
2.3.3 Removing obstacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  11

210109379 I
 Tableofcontents

2.3.4 Extending the reach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  11

2.3.5 Extending the placing boom and end hose . . . . . . . . . . . . . . 2  12
2.3.6 Impermissible end hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  12
2.3.7 Impermissible working area . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  13
2.3.8 Climbing the placing boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  13
2.3.9 High−pressure delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  14
2.3.10 Accessories and attachments . . . . . . . . . . . . . . . . . . . . . . . . . 2  14

2.4 Exclusion of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 14

2.5 Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 14
2.5.1 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  15
2.5.2 Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  15
2.5.3 Responsibility of the machine operator . . . . . . . . . . . . . . . . . . 2  15

2.6 Operating Instructions, operating procedures

and other regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 16
2.6.1 Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  16
2.6.2 Operating procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  17
2.6.3 Other regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  17

2.7 Personal protective equipment . . . . . . . . . . . . . . . . . . . . . . . 2 — 18

2.8 Before starting work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 20

2.8.1 Checking that the machine is ready for operation . . . . . . . . 2  20
2.8.2 Rendering the machine ready for operation . . . . . . . . . . . . . 2  20

2.9 Danger due to high–voltage . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 21

2.9.1 High−voltage lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  21
2.9.2 Discharge voltage pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  21
2.9.3 Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  21
2.9.4 High−voltage warning devices . . . . . . . . . . . . . . . . . . . . . . . . . 2  23
2.9.5 Procedure in the event of a flash over . . . . . . . . . . . . . . . . . . . 2  23
2.9.6 Earthing in the event of electrostatic charging . . . . . . . . . . . 2  24

2.10 Stationary machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 25

2.10.1 Set−up site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  25
2.10.2 Stationary booms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  25
2.10.3 Lifting machines and components . . . . . . . . . . . . . . . . . . . . . . 2  26
2.10.4 Loading and transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  26

2.11 Mobile machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 27

2.11.1 Set−up site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  27

II 210109379
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2.11.2 Supporting ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  28

2.11.3 Corner bearing loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  29
2.11.4 Supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  30
2.11.5 Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  32
2.11.6 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  33
2.11.7 Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  34

2.12 Placing booms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 35

2.12.1 Unfolding the placing boom . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  35
2.12.2 Guiding the end hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  37
2.12.3 Guiding the end hose ergonomically . . . . . . . . . . . . . . . . . . . 2  38
2.12.4 Connecting drills . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  38
2.12.5 Procedure in storms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  39
2.12.6 Concreting in cold weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  39

2.13 Delivery line systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 40

2.13.1 Suitable delivery lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  40
2.13.2 Securing delivery lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  40
2.13.3 Tightness and blockages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  41
2.13.4 Opening delivery lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  42
2.13.5 Clearance to delivery lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  42
2.13.6 Fastening delivery lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  42
2.13.7 Continuation delivery lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  43
2.13.8 Devices for shutting−off, diverting or cleaning delivery lines 2  43

2.14 Pumping operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 44

2.14.1 Place of work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  44
2.14.2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  44
2.14.3 Remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  44
2.14.4 Moving machine components and hot surfaces . . . . . . . . . . 2  45
2.14.5 Constant observation of the machine . . . . . . . . . . . . . . . . . . . 2  45
2.14.6 Truck mixer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  45

2.15 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 46
2.15.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  46
2.15.2 Cleaning agents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  47
2.15.3 Cleaning with compressed air . . . . . . . . . . . . . . . . . . . . . . . . . 2  48
2.15.4 Protection against water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  49
2.15.5 Post−cleaning procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  49

210109379 III
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2.16 Requirements for special work . . . . . . . . . . . . . . . . . . . . . . . 2 — 50

2.17 Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 52

2.18 Working on the placing boom . . . . . . . . . . . . . . . . . . . . . . . . 2 — 53

2.19 Safety-relevant components . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 53

2.20 Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 54

2.21 Protective and safety equipment . . . . . . . . . . . . . . . . . . . . . 2 — 54

2.22 Electrical power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 55

2.22.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  55
2.22.2 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  56
2.22.3 Power at the construction site . . . . . . . . . . . . . . . . . . . . . . . . . . 2  56

2.23 Hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 57

2.23.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  57
2.23.2 Replacing hydraulic hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  58

2.24 Noise emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 58

2.25 Exhaust fumes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 59

2.26 Functional fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 59

2.27 Disposal of the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 60

IV 210109379
 Tableofcontents

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

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  59
3.6.4 Fuse box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  62
3.6.5 Cable remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  63
3.6.6 EMERGENCY STOP button . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  65
3.6.7 Agitator safety cutout (RSA) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  67
3.6.8 Magnetic switches distributor casing . . . . . . . . . . . . . . . . . . . 3  69
3.6.9 Magnetic switch connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  72

210109379 V
 Tableofcontents

3.7 Hydraulic control devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 74

3.7.1 Output controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  75
3.7.2 Pump control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  76
3.7.3 Pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  77
3.7.4 Filter condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  77

3.8 Other components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 78

3.8.1 Hydraulic fluid radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  79
3.8.2 Vibrator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  80

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 withconcrete . . . . . . . . . . . . . . . . . . . . . . . . . 4  5

4.2 Test run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 — 6

4.2.1 Switching on themachine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Acknowledge the agitator safety cutout . . . . . . . . . . . . . . . . . 4  14
4.3.5 Filter condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  16
4.3.6 Agitator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  18
4.3.7 Vibrator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  19
4.3.8 Switching off themachine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  20

VI 210109379
 Tableofcontents

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 F8 chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  4
5.1.5 F25 chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  4
5.1.6 F80 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 — 19

5.5.1 Danger zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  20
5.5.2 Instructions for laying the line . . . . . . . . . . . . . . . . . . . . . . . . . . 5  21
5.5.3 Fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  23
5.5.4 SK delivery line system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  27

210109379 VII
 Tableofcontents

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 Considering concrete properties . . . . . . . . . . . . . . . . . . . . . 6 — 6

6.5 Filling the agitator hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 7

6.6 Starting pumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 8

6.7 Pumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 9
6.7.1 Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  10
6.7.2 Blockages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  12
6.7.3 Breaks in pumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  13
6.7.4 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  14
6.7.5 Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  14
6.7.6 Restarting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  16

6.8 Emergency operation – pump function . . . . . . . . . . . . . . . 6 — 17

6.9 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 19
6.9.1 Preparations forcleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  22
6.9.2 Delivery line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  28
6.9.3 Hopper, delivery cylinder and Stransfer tube . . . . . . . . . . . . 6  35
6.9.4 Post
cleaning procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  41

6.10 Measures for preserving the value of concrete pumps

and placing booms in storage . . . . . . . . . . . . . . . . . . . . . . . . 6 — 43

VIII 210109379
 Tableofcontents

7 Maintenance
7.1 Daily tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 — 1
7.1.1 Daily visual checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7  1
7.1.2 Function check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7  2
7.1.3 When pumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7  3
7.1.4 After every job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7  3

7.2 Maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 — 4

7.2.1 As required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7  4
7.2.2 Regular maintenance tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7  5

7.3 Residual risks during maintenance, inspection

and repair work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 — 7
7.3.1 Personal protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . 7  7
7.3.2 Personnel requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7  7
7.3.3 Auxiliary devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7  7
7.3.4 Residual risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7  8

7.4 General tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 — 10

7.4.1 Set screws and nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7  10
7.4.2 Flared screwed joint, reassembly . . . . . . . . . . . . . . . . . . . . . . . 7  11
7.4.3 Profiled ring joint, reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 7  11

7.5 Functional fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 — 12

7.5.1 Hydraulic fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7  12
7.5.2 Level of contaminant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7  14
7.5.3 Lubricant analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7  14
7.5.4 Storage of lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7  14

7.6 Lubricant recommendation . . . . . . . . . . . . . . . . . . . . . . . . . . 7 — 15

7.6.1 Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7  17
7.6.2 Greases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7  18
7.6.3 Hydraulic fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7  19

210109379 IX
 Tableofcontents

Maintenance cards
00−001 Visual checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7  23
03−002 Function checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7  25
03−010 Changing the hydraulic fluid . . . . . . . . . . . . . . . . . . 7  27
04−002 Hydraulic hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7  31
04−005 Vacuum meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7  35
04−013 Changing the pressure filter element . . . . . . . . . . 7  37
06−023 Delivery piston replacement . . . . . . . . . . . . . . . . . . 7  43
07−069 Replacing the transfer tube bearing . . . . . . . . . . . 7  49
07−070 Replacing the switching shaft bearing
(flanged bearing) . . . . . . . . . . . . . . . . . . . . . . . . . . . 7  55
07−071 Replace the spectacle wear plate . . . . . . . . . . . . . 7  71
07−072 Replacing the Stransfertube . . . . . . . . . . . . . . . . . 7  85
07−073 Replacing the Stransfertube wear sleeve . . . . . 7  93
07−074 Replacing the thrust ring and wear ring . . . . . . . . 7 101
07−075 Adjusting the Stransfertube . . . . . . . . . . . . . . . . . 7 107
07−078 Resolver on the switching shaft . . . . . . . . . . . . . . . 7 121
08−007 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 123
10−007 Measuring the wall thickness
(Machines with Stransfer tube) . . . . . . . . . . . . . . . 7 125
10−044 Measuring the wall thickness of two−layer pipes 7 131

X 210109379
 Tableofcontents

Index of key words

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

210109379 XI
 1 Guide to the Operating Instructions

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

Putzmeister Condrete Pumps GmbH

After Sales Department
Max−Eyth−Straße 10
D−72631 Aichtal
Germany
Telephone +49 7127 599−0
Telefax +49 7127 599−520
e−mail: [email protected]

or the Branch or Works Agency that looks after you.

Address:

Telephone:

Telefax:

e−mail:

BP01_001_0802EN
 GuidetotheOperatingInstructions

1.1 Foreword The aim of these Operating Instructions is to familiarize the user with
the machine and to assist him in using the machine properly in vari

ous operations.

The Operating Instructions contain important information on how to

operate the machine safely, properly and economically. Observing
these instructions helps to avoid danger, to reduce repair costs and
downtimes, and to increase the reliability and service life of the
machine.

The Operating Instructions must be supplemented by the relevant

national rules and regulations for accident prevention and environ

mental protection.

The Operating Instructions must always be available wherever the

machine is in use.

These Operating Instructions must be read and applied by any

person 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 of
fuels and consumables;
− in service (maintenance, inspection, repair); and/or
− transport.

The generally−recognized rules of technology for safe and proper

working must be observed in addition to the Operating Instructions
and mandatory rules and regulations for accident prevention and
environmental protection in the country and place of use of the
machine.

AP01_002_0802EN 11
 GuidetotheOperatingInstructions

The Branch or Agent serving you, or the Aichtal Works, will be happy
to 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 you
can give us the details of the machine model and the machine
number.

These Operating Instructions do not describe the engine; the en

closed operating instructions issued by the engine manufacturer
apply for this.

Modifications are made from time to time in the interests of constant

improvement and it could be possible that we were unable to take
these into consideration when these Operating Instructions were
printed.

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

The reproduction, distribution and utilization of this document as well

as the communication of its contents to others without explicit author

ization is prohibited. Offenders will be held liable for the payment of
damages. All rights reserved in the event of the grant of a patent,
utility model or design.

© Putzmeister Concrete Pumps GmbH 1994

12 AP01_002_0802EN
 GuidetotheOperatingInstructions

1.2 Icons and symbols The following icons and symbols are used in the Operating
Instructions:

" Task symbol

Text following this symbol describes tasks which you are required to
work through from top to bottom in the sequence shown.

å 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 currently
reading.

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 the
truck, are not specially listed.

Environmental protection
Particular specifications regarding environmental protection are
introduced by the icon shown, the words
Environmental protection"
printed in bold, and a line. The associated text is printed in italics
and ends with another line.

Note
Particular information regarding the economic use of the machine is
introduced by the icon shown, the word
Note" printed in bold, and
aline. The associated text is printed in italics and ends with another
line.

Caution
Particular information or rules or prohibitions intended to prevent
damage are introduced by the icon shown, the word
Caution"
printed in bold, and a line. The associated text is printed in italics
and ends with another line.

BP01_003_0601EN 13
 GuidetotheOperatingInstructions

Danger
Particular information or rules or prohibitions intended to prevent
personal injury or significant damage are introduced by the icon
shown, the word
Danger" printed in bold, and a line. The associated
text is printed in italics and ends with another line.

The appropriate icon will be used if it is possible to identify the source

of the danger precisely.

Danger of fire
This icon is used to identify actions for which there is a particular
danger of fire.

Danger of explosion
This icon is used to identify actions during which there is the danger
of an explosion. The explosion may also be caused by pressure
being released suddenly.

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

Danger of crushing
This icon is used to identify actions during which there is the danger
of being crushed.

14 BP01_003_0601EN
 GuidetotheOperatingInstructions

Suspended load
This icon is used to identify actions in which suspended loads may
fall down.

High voltage
This icon is used to identify actions in which there is the danger of
electrocution, possibly with lethal consequences.

Danger of burning
This icon is used to identify actions in which there is a danger of
burning from chemical substances which are not specifically
described.

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

Danger of poisoning
This icon is used to identify actions in which there is a danger of
poisoning by inhalation of gases, ingestion of or contact with
substances.

BP01_003_0601EN 15
 2 Safety regulations

This chapter corresponds to the contents of the VDMA brochure

entitled

Safety manual Concrete delivery and placing machines".

Here you will find a summary of the most important safety regula

tions. This chapter is, therefore, particularly suitable as an initial
basic instruction for new operators.

Note
Special safety regulations may be necessary for some tasks. These
special safety regulations will only be found in the description of the
particular task.

We include here a listing of regulations and safety standards for your

information:
 EN 12001, Conveying, spraying and placing machines for
concrete and mortar
 EN 12100, Safety of machinery,
 EN 60204−1, Electrical equipment of machines.
 in the Federal Republic of Germany: BGR 182, Betonpumpen und
Verteilermaste

BP03_077_1001EN
 Safetyregulations

2.1 Definition of terms The terms used in this Safety Manual are explained below, along with
descriptions of the requirements placed on specific groups of
people.

2.1.1 Machine In this Safety Manual, concrete delivery and placing machines refer
to:
− Truck−mounted concrete pumps (ensemble of truck, concrete
pump with and without placing boom). The truck manufacturer’s
Safety Manual also apply to the truck.
− Truck mixer concrete pump (an ensemble of truck mixer, concrete
pump and placing boom). The Safety Manual issued by the truck
mixer manufacturer and by the truck manufacturer also apply to
truck mixer concrete pumps.
− Stationary concrete pumps
− Stationary placing systems (an ensemble of placing boom and
base structure)

2.1.2 Concrete pump For the purposes of this Safety Manual, concrete pumps are defined
as devices which are designed to deliver concrete to placement
sites via pipes or hoses.

2.1.3 Boom pedestal In this Safety Manual, boom pedestal refers to a device for holding
and guiding an arm assembly.

2.1.4 Arm assembly For the purposes of this Safety Manual, arm assemblies are powered
slewable devices consisting of one or more swinging or folding sec

tions for guiding the delivery line.

2.1.5 Placing boom In this Safety Manual, placing boom refers to a unit comprising the
arm assembly and boom pedestal.

2.1.6 Base structure For the purposes of this Safety Manual, base structures are defined
as equipment which is designed to hold a stationary placing boom to
give the latter the required stability.

BP03_076_1601EN 21
 Safetyregulations

2.1.7 Truck mixer In this Safety Manual, truck mixers are vehicles with mixing equip

ment for transporting concrete.

2.1.8 Delivery line systems For the purposes of this Safety Manual, delivery line systems are de

fined as self−contained pipes or hoses in which concrete is pumped
from the concrete pump to the placement site. Devices for shutting−
off, diverting or cleaning delivery lines can be integrated into delivery
line systems.

2.1.9 Guiding the end hose The "end hose" as referred to in this Safety Manual is the hose that is
fitted on the arm assembly at the end of the delivery line for distribut

ing the concrete. There must be no couplings, spouts, discharge
stops or other items fixed to the outlet end of the end hose unless
they are approved by the manufacturer.

2.1.10 Manufacturer Any natural or legal person that markets a machine or incomplete
machine that is dealt with in this Safety Manual

2.1.11 Operator Authorized representative of the owner of the concrete pumps and/or
placing booms. The operator is responsible for the use of these ma

chines.

2.1.12 Machine operator Person trained in and charged with the operation of concrete pumps
and placing booms.

2.1.13 Hoseman Persons instructed by the site management in how an end hose is
guided. Hosemen must be able independently to evaluate danger

ous situations which may occur in the area of the end hose and react
according to the situation.

2.1.14 Signaller and other Persons instructed by the site management to help the machine op

auxiliary personnel erator in his work if the latter is unable to observe all areas of oper

ation and danger zones. Signallers must be able to independently
evaluate all dangerous situations which may occur when working
with a concrete pump and/or placing boom, and to react according
to the situation. The signaller must have a suitable means of com

munication with the machine operator.

22 BP03_076_1601EN
 Safetyregulations

2.1.15 Truck mixer driver Person who supplies the concrete pump with concrete from a truck
mixer. 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 when
working in the area of the hopper of a concrete pump, and to react
according to the situation.

2.1.16 Authorized inspector Authorized inspectors are persons empowered by the relevant gov

ernment bodies to carry out this task of inspection. The prerequisites
for becoming an authorized inspector are:
− To have completed a higher education course in engineering or
similar.
− To have at least 5years’ professional experience in a relevant do

main, of which at least six months must have involved participation
in the work of an authorized inspector.
− To possess thorough knowledge of the relevant health and Safety
Manual, as well as of directives and the generally recognised rules
of engineering.
− To have access to the necessary equipment to carry out the in

spection.
− To be able to carry out the tasks impartially.

2.1.17 Subject expert For the purposes of this Safety Manual, a subject expert is a person
who, through their professional training, their professional experience
and their recent professional activity, has the required specialist
knowledge to inspect the tools.

2.1.18 Qualified personnel Persons who have completed specialist training for a particular activ

ity which qualifies them to carry out their roles.

2.1.19 After Sales Service Qualified persons employed by the manufacturer who are respon

personnel sible in particular for maintenance of the machine.

2.1.20 Maintenance Maintenance embraces all measures required for inspection, servic

ing and repair of a machine.

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 Safetyregulations

2.1.21 Place of work, working area, danger zone

Mobile machines
14 6 7
2

1 6

10

3
11

12
5

ab0005

Example

Stationary machines
14 11

4 10

4 9
3

3 6 6 1 2

13
13 13
1
5

11 12

ab0010

Example

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Pos. 0 Designation Explanation

1 Machine operator In normal operation, with the remote control
2 Place off work
Pl k Hoseman At the end hose in the danger zone
(during pump

pump
3 Signaller In the machine operator’s range of vision
ing oper

oper
4 Auxiliary personnel As manual placing system operators
ations)
5 Truck mixer driver At the hopper in the danger zone
Area with a radius of the reach of the placing boom
6 Permitted
+ end hose length
Working area
The end hose must not be moved backwards be

7 Impermissible
yond the vertical of the placing boom
Risk of injury when pumping is started, during
pumping operations, when removing a blockage
8 At the end hose
and during washing out procedures. The diameter
of the danger zone is twice the end hose length.
Beneath the placing
9 Risk of injury from falling items
boom
Area of the support
legs and feet Danger of crushing when the machine is set up and
10 Danger zone
or area of the base when the supports are retracted
structure
Any presence on or below the machine when the
11 On the machine
pump is in operation is prohibited
Risk of injury during washing out procedures and
12 at the hopper
when the hopper is being filled using a truck mixer
Area of the delivery Hazard posed if lines burst, risk of injury from crush

13
line systems ing or shearing, particularly with gate valves
14 Structure or area being concreted Example

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 Safetyregulations

Place of work The place of work is the area in which people must remain in order to
carry out the work.

Place of work − ma The machine operator’s place of work is with the remote control when
chine operator the pump is in operation. The place of work must be selected so as
to allow visual contact with the site of concrete placement, and the
truck mixer driver, and so that the working area can be observed at
the same time. A signaller must otherwise be used.

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

Place of work − hose The hoseman’s place of work is within the danger zone of the end
man hose, but not beneath the placing boom. This requires a greater level
of caution. The hoseman and machine operator must have visual
contact.

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

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

The working area must be secured and clearly identified. Suitable

personal protective equipment is required in the working area. The
machine operator is responsible for safety in the working area of the
machine whilst the machine is in use.

Impermissible working Because of their high manoeuvrability, some placing booms can also
area be shifted into positions for which they are not designed. This may
overload or damage the placing boom. Placing booms must there

fore only be moved within the permitted working area.

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Danger zone The danger zone is the area surrounding the machine, in which
people may be at risk of injury from movements required by the
work.

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

Depending on the working situation, workplaces may occasionally

fall within the danger zone, especially the workplace of the hoseman
and the truck mixer driver. If a workplace falls within the danger
zone, increased caution is required and suitable personal protective
equipment is prescribed. Persons who are authorized to be present
in such a workplace, must use their own discretion to assess the
hazards of the situation and be able to react accordingly.

The machine operator is responsible for safety in the danger zone of

the machine whilst the machine is in use.

The machine operator must stop work immediately and press the
EMERGENCY STOP button if an unauthorized person enters the
danger zone.

Support legs and sup There is a danger of crushing in the swing
out and extension zone
port feet for the supports.

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

BP03_076_1601EN 27
 Safetyregulations

Machine All the time the vehicle is in operation, there is a risk of injury on and
below the machine from moving parts and bursting delivery lines or
hydraulic hoses, as well as a risk of falling on slippery surfaces or
steps.

Guiding the end hose The danger zone when pumping is started, during pumping oper

ations, when removing a blockage and during washing out pro

cedures is the area around the end hose in which the hose may
swing out. The diameter of the danger zone is twice the end hose
length.

Hopper 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 with
concrete. There is a risk of being crushed and of injury by shearing
from the transfer tube. There is a risk of being entrapped by the ro

tating agitator.

Delivery line systems In the area around the delivery line systems there is a risk of injury
from 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.

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2.2 Designated use The machine must only be operated as intended and in technically
perfect condition. All protective and safety
oriented devices, particu

larly removable protective devices and EMERGENCY STOP devices,
must be available and fully functional.

The machine is designed exclusively for the delivery and placing of

concrete up to a bulk density of 2400 kg/m3. It must only be used for
pumping operations on construction sites. The maximum concrete
pressure must not exceed that specified on the rating plate or in the
check book.

You must also observe the Safety Manualand comply with the inter

vals and conditions for inspections (particularly retesting) and main

tenance work in order to operate the machine within the limits of its
proper use.

2.2.1 Retesting (safety in- After initial commissioning of the machine, the operational safety of
spection) the machine must be checked regularly by a subject expert. The in

spection intervals depend on the age of the machine. The older the
machine, the greater the probability of damage. This is why regular
retesting of the machine, appropriate to its age, is an effective
means for the early detection of damage.

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 and
other changes;
− retesting of the completeness and effectiveness of the safety
equipment;
− retesting to find out whether any defects which are found during
the tests mentioned above and which could affect safety have
been adequately rectified.

Furthermore, information provided by the manufacturer to the oper

ator with reference to special instructions for maintenance and in

spection must be observed.

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2.2.2 Inspection intervals The inspection intervals are fixed as follows:

for retesting
Machines of up to and including 5years old:
Inspect after every 1,000operating hours or 1year, whichever is
soonest. The interval is repeated after every retest.

Machines more than 5years old:

Inspect after every 500operating hours or 1year, whichever is
soonest. The interval is repeated after every retest.

Machines more than 10years old:

Inspect after every 250operating hours or 1year, whichever is
soonest. The interval is repeated after every retest.

The day of initial commissioning in accordance with the handover

report and the machine’s operating hours meter are definitive for the
intervals. This operating hours meter records the hours of pumping
operations. The operating hours meter must always be kept in good
working order. It must not be tampered with. For machines without an
operating hours meter, the operating hours must be comprehensibly
recorded in writing.

Retesting must be arranged by the operator. The results of retesting

must be entered in the check book and signed. The check book
must always be kept with the machine and must be produced upon
the request of the national supervisory bodies.

Notwithstanding national legislation, the operator can be liable in the

event of damage, if it is proved that the damage has arisen as a
consequence of regular retesting not being properly carried out.

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

ing must be carried out.

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2.3 Use contrary to desig- Any use of the machine which is not described in section 2.2,en

nated use 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 from such
use. Some examples of conceivable uses that are contrary to the
designated use are given below.

2.3.1 Transporting goods The machine may not be used for the transport of goods, except for
carrying the accessories used for the machine, such as pipes,
hoses, etc. The maximum permissible gross weight may not be ex

ceeded.

2.3.2 Lifting loads The placing boom must never be used for lifting loads.

wz0006

2.3.3 Removing obstacles The placing boom must not be used under any circumstances to re

move obstacles. This would overload the placing boom, causing
damage and endangering people.

2.3.4 Extending the reach 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 the
reach or to pump at an angle. Since the boom and the lifting equip

ment for the extension have differing pivot points and modes of con

trol, it is not possible to co−ordinate their movements.

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2.3.5 Extending the placing Extension of the placing boom and end hose beyond the length
boom and end hose specified on the rating plate is forbidden.

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

If a longer end hose is used, the diameter of the danger zone is also
increased (see also page237).

End hoses with a length of more than 4m must not be guided by
hand.

wz0016

2.3.6 Impermissible end There must be no couplings, spouts, discharge stops or other items
hose fixed to the outlet end of the end hose unless they are approved by
the manufacturer.

wz0195

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2.3.7 Impermissible work- The end hose must not be moved backwards beyond the vertical of
ing area the placing boom.

wz0026

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

wz0037

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2.3.9 High–pressure deliv- It is prohibited to deliver concrete at high−pressure (concrete pres

ery sure greater than 85 bar) through the delivery line of the placing
boom. Delivery line elements are marked with the maximum permiss

ible delivery pressure. The delivery line and end hose are only suit

able for concrete pressures of up to 85 bar until the wear threshold is
reached. For the wear threshold, refer to the Safety Manualfor the
machine.

2.3.10 Accessories and at- It is prohibited to fit accessories and attachments to the machine if
tachments they have not been expressly approved for use on this machine by
the manufacturer.

2.4 Exclusion of liability Where the manufacturer’s delivery conditions are agreed, liability will
be as described in the provisions there. The manufacturer is not li

able for damage in cases specified there.

Unless the responsibility of the manufacturer, the warranty will be in

validated 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 manu

facturer
− adjustment of safety pressures, speeds of movement, power out

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

2.5 Personnel The operator must ensure that only persons who are qualified or
have received the necessary instruction work on or with the machine.
You can ask the machine manufacturer for suitable training. He must
clearly define who is responsible for operation and maintenance of
the machine. He must also ensure that only persons commissioned
to work on the machine do so.

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2.5.1 Requirements Persons operating or carrying out maintenance work on the machine
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 maintenance
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 covered by
a hair net. There is a risk of injury, in particular from being caught or
trapped by moving parts.

All persons working on or with the machine must concentrate on the

task at hand and not be distracted, particularly by smartphones and
music played through headphones.

2.5.2 Qualifications Do not allow persons who have not yet completed training or instruc

tion, or persons taking a general training course, to operate the ma

chine unless under the constant supervision of an experienced per

son.

If you do not have qualified personnel, suitable workshop equipment

etc. available, you should commission the manufacturer’s After Sales
Department with the maintenance of your machine.

2.5.3 Responsibility of the The operator must define the responsibility of the machine operator
machine operator (including in respect to national road traffic regulations) and em

power him to reject instructions from third parties prejudicial to
safety. The machine operator must be able to reject the site of oper

ations if he has doubts regarding technical safety.

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2.6 Operating Instructions, operating procedures and other regulations

2.6.1 Operating Instruc- Personnel that are authorised to work on the machine must have
tions read the Operating Instructions before working with the machine,
particularly the section Safety Regulations and the Safety Manual.
Reading the instructions after work has begun is too late. This
applies especially to persons working only occasionally on the ma

chine, e.g. during setting up or maintenance.

The Operating Instructions and check book must always be kept to

hand at the site of use of the machine (in the tool compartment or
container provided for this purpose).

As the operator, you must always make sure that the Operating In

structions are available. Have personnel working on the machine
confirm in writing their knowledge, understanding and application of
the Operating Instructions and Safety Regulations and Safety Man

ual. At regular intervals of at least once a year, check that personnel
are conscious of safety and the hazards involved in their work and
are taking account of the Operating Instructions.

Personnel entrusted with work on the machine must observe all

safety instructions and hazard warnings, and must be familiar with
the machine itself. You must practice all the operating procedures
described in the Safety Manual (extending the supports, operating
the placing boom, shifting the placing boom into the driving position,
preparing the vehicle for moving, etc.) under the supervision of a
subject expert until you are certain you can execute them safely. Ask
questions if there is something you have not understood. Begin oper

ating the machine only once you are familiar with the layout and sig

nificance of all the control and monitoring devices and the function

ing of the machine in general.

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2.6.2 Operating procedures The operator must produce operating procedures for his personnel
in accordance with national regulations. These operating procedures
must include instructions covering the duties involved in supervising
and notifying special organisational features, e.g. organization of
work, working procedures or the personnel entrusted with the work.
Furthermore, reference must be made to other generally valid legal
and otherwise mandatory regulations relating to accident prevention
and environmental protection. Such regulations may also deal with
handling hazardous substances, the issuing and wearing of personal
protective equipment or with national road traffic regulations. You
should familiarise yourself with the site of operations and with how to
use fire extinguishers. Observe the fire
alarm and firefighting pro

cedures.

2.6.3 Other regulations The current regulations for concrete delivery and placing machines
as issued by:
− the legal authorities in your country
− national supervisory bodies
− the responsible commercial liability insurance company are bind

ing on the operator of the machine.

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2.7 Personal protective In order to reduce risks to personnel, personal protective equipment
equipment must be used in so far as this is necessary or deemed to be so by
regulations. All personnel working on or with the machine must wear
safety helmets, protective gloves and safety footwear.

Personal protective equipment must, as a minimum, comply with the

requirements of the specified standards.

Safety helmet
A safety helmet protects your head against, for instance, falling
concrete or parts of the delivery line in the event of a hose bursting.
(DINEN397; Industrial safety helmets)

Safety footwear
Safety footwear protects your feet against falling objects and
against penetration by projecting nails.
(ENISO20345; Safety footwear for professional use; CategoryS3)

Hearing protectors
Hearing protectors protect you against the noise generated by the
machine when you are standing close to it.
(DINEN352−1; Hearing protectors − General requirements − Part1:
Earmuffs
or
DINEN352−3; Hearing protectors − General requirements − Part3:
Earmuffs on safety helmet)

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Protective gloves
Protective gloves protect your hands against aggressive or chemi

cal substances, as well as against mechanical effects (e.g. impact)
and cutting injuries.
(DINEN388; Protective gloves against mechanical risks; Class
1111)

Protective goggles
Protective goggles protect your eyes against injuries from concrete
spatters or other particles.
(DINEN166; Personal eye
protection − Specifications)

Safety harness
When working at height, use the climbing aids and working plat

forms provided for reasons of safety or wear a safety harness. The
relevant national regulations must be complied with.
(DINEN361; Personal Protective Equipment Against Falls from a
Height − Full Body Harnesses; CategoryIII)

Face mask and respiratory protection

A face mask and respiratory protection protect you against parti

cles of building materials which could enter your body through your
respiratory passages (e.g. concrete admixtures).
(DINEN149; Respiratory protective devices − Filtering half masks
to protect against particles − Requirements, testing, marking;
ClassFFP1)

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2.8 Before starting work

2.8.1 Checking that the ma- As machine operator, it is your responsibility to check the machine
chine is ready for for external damage and defects before any use of the machine. You
operation must immediately report any changes (including changes in the
working characteristics) to the organization or person responsible. If
necessary, shut the machine down and secure it against use.

2.8.2 Rendering the ma- As machine operator, you are responsible for rendering the machine
chine ready for oper- ready for operation. This also includes topping up the functional
ation fluids. Do not fill with fuel in enclosed spaces. Switch off the engine
and the heating. Wipe up spilt fuel immediately. Do not smoke or use
a naked flame when handling fuel.

Set all the control and monitoring devices to the zero position before
you change the mode of control (control block, control console or
remote control). Press the EMERGENCY STOP button. otherwise the
machine might execute unintended movements.

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

Never leave the machine when the engine is running or when the en

gine could be started by an unauthorized person. If you need to
leave 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.

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2.9 Danger due to high–voltage

2.9.1 High–voltage lines Whenever you touch a high−voltage line, there is a risk of death for
all 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 can
jump across from a high−voltage line even if you just approach it and
this will energize the machine and the surrounding area.

2.9.2 Discharge voltage In the event of a flash over, what is known as a discharge voltage
pattern pattern" 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 within this discharge voltage pattern, you will bridge
different potentials. This will cause a voltage corresponding to the
potential difference to flow through your body.

2.9.3 Clearances Maintain a minimum clearance from high−voltage lines in accord

ance with the following table. The minimum clearance is measured in
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 country of
use.

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wz0116

When you set a minimum clearance, the possibility of the high−volt

age lines and the placing boom swaying in the wind must also be
taken into consideration. You should further note that where air hu

midity is high, clearances greater than the minimum clearances
shown above are always necessary.

You must stand as close as possible to the unfolded placing boom if

you wish to estimate correctly the movements of the boom and,
above all, the clearance between the placing boom and obstacles or
high−voltage lines.

The same minimum clearances are necessary when driving under

overhead cables.

In the event that this minimum clearance cannot be maintained

under all possible working positions, the power station responsible
must be contacted and you must have the high−voltage line
switched off.

Should you have any doubts, it is better to forego the use of the plac

ing boom and to lay a separate delivery line, for instance.

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2.9.4 High–voltage warning According to the current rules of engineering, high−voltage warning
devices devices do not meet a safety standard which enables a safe under

shooting of the required minimum clearances to high−voltage lines.
Previous experience has shown that high−voltage warning devices
cannot make all situations in working procedures safe. Flash overs
and fatal accidents can occur despite the use of a high−voltage
warning device. You must therefore always maintain the minimum
clearances mentioned above.

2.9.5 Procedure in the Should a flash over occur, despite all precautions, stay calm, do not
event of a flash over move (potential differential), touch nothing.

wz0126

If your machine comes into contact with heavy current lines:

− Warn those outside against approaching and touching the ma

chine.
− 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.

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Power stations are always equipped with automatic switch−on de

vices. If a circuit breaker trips, the short−circuited cable will be
switched back on again after a brief interval. Brief intervals when the
voltage is absent give rise to a false sense of safety.

You should only move and rescue injured persons once a represen

tative of the power station has notified you that the cable has been
switched off.

A radio remote control system only protects the machine operator if

he is standing outside the discharge voltage pattern.

2.9.6 Earthing in the event Faults can be caused in the radio remote control system and dan

of electrostatic charg- gerous electrical charging of the machine can occur when working
ing in the vicinity of transmitters (radio transmitter, etc.). Persons who
bridge the charged parts to the earth are heavily charged on con

tact.

Machines in use in the vicinity of transmitters must be earthed. Se

cure the earthing cable (atleast 16mm2) to a specially prepared,
bare metal point of the machine (in particular, not to a piston rod)
and to a conductive metal rod in the ground (minimum insertion
depth of 1.5m). Thoroughly dampen the earth around the metal rod
to make it more conductive.

Even when the machine is earthed, the safe clearances to high−volt

age lines (see also page221) must be maintained and the in

structions regarding storms and bad weather (see also
page239) must be observed.

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

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2.10 Stationary machines

2.10.1 Set–up site Stationary machines are generally used on a construction site for a
lengthy period. For this reason, site management should prepare the
set
up site carefully. The site management must deliver the necess

ary documents in good time in order to be able to prepare the
foundations, base plates or similar on time.

When selecting the set
up site, remember that the machine must be
dismantled 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.

2.10.2 Stationary booms Stationary booms can be erected on tubular columns, lattice booms
or other base structures. The base/structural elements to which the
base structure is fixed must be able to withstand the forces and mo

ments transferred via the base structure, as specified in the manu

facturer’s information. The base frame of the base structure must be
fastened in place so that it is level on the base/structural elements in
every direction. Check the documentation provided by the manufac

turer in this regard and the corresponding notes in the operating in

structions.

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2.10.3 Lifting machines and Machines which are transported to the set
up site in individual parts
components or not under their own power must only be lifted with suitable lifting
equipment in accordance with the specifications in the Operating
Instructions. The lifting gear on the machine must be capable of ac

cepting the lifting gear and lifting the load. No
one should stand
under suspended loads. Before work is started, a subject expert
must check that the assembled machine is working properly.

2.10.4 Loading and trans- Only use suitable means to load and transport stationary machines.
porting Ensure that no
one can be injured by the machine tipping over or
slipping.

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 traffic
regulations in the country concerned if they are to use the public
highway.

Please also observe section 2.11.5,Mobile machines, driving.

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2.11 Mobile machines

2.11.1 Set–up site It is the machine operator who takes responsibility for setting up the
machine safely. He must inspect the proposed set
up site and must
refuse to set the machine up at the site of operations if he has any
doubts regarding safety.

As machine operator, you must familiarise yourself with the working

area and surroundings before work is begun. The working area and
surroundings include, in particular, obstacles in the work and travel

ling areas, the loadbearing capacity of the supporting ground and
any barriers separating the construction site from public roads.

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

Do not park 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 avoided
as far as possible. If this is not possible, special care and attention is
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 is
suitable, prepare the route before work is started. It is especially
necessary to walk the approach route once in darkness and at dusk
or dawn. You should repeat this exercise again before leaving the
construction site.

You must always ask for a signaller if you have to reverse. If necess

ary, have the approach route closed off or secured by signallers.
Have any materials or equipment that hinder your approach re

moved.

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2.11.2 Supporting ground Find out the load−bearing capacity of the supporting ground. The
site management will be able to state the permitted ground pressure.
If the load−bearing capacity is unknown, assume the that worst case
scenario applies.

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The supporting ground must be level and even. If necessary, set up

a level surface on top of the uneven ground. There must be no voids
or other ground irregularities under the support feet. Asphalt, con

crete slabs, etc. may have been washed out underneath. Never set
the machine up on backfilled ground, obvious or known voids or un

even ground.

The support area must be enlarged as required. Support blocks and

timber blocks may be used to increase the support area. The sup

port timbers must be undamaged and free from ice, oil, grease, etc.
The support blocks and timber blocks must be laid under the sup

port plates such that the load is distributed uniformly and the sup

port 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

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2.11.3 Corner bearing loads The corner bearing load is stated on each support leg. This value
must always be legible.

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The force transferred to the ground by each support leg diffuses

through the soil in a conical pattern at an angle of 45_. Safe clear

ance to the pits and slopes must be maintained, and such clearance
must be determined in accordance with the nature of the ground.
The safe clearance is measured from the foot of the pit.

However, for undisturbed, compacted ground, the safe clearance

corresponds to pit depth, but must be a minimum of 2m.

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

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2.11.4 Supports The placing boom must not be raised until the machine has been
supported in accordance with the Operating Instructions. There is
otherwise a risk of the machine toppling over.

Swing out and telescope the support legs to their end positions in
sequence. Intermediate positions are prohibited to guarantee stabil

ity. Exceptions are machines which have been equipped by the
manufacturer with a device which allows secure erection with a re

duction in support. Check the corresponding notes in this regard in
the operating instructions.

Do not carry out more than one movement at a time. If a movement is

stopped, the entire volume of fluid is available for the remaining
movements, and can increase their speeds. Depending on the de

sign, it may be the case that carrying out several movements at once
(as opposed to carrying out a single movement at maximum speed
at any one time) does not bring any advantage in terms of time.
Carrying out several movements at once requires an increased 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 cause
the supports to sink on one side.

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The machine must be made level in all directions. Provided the

manufacturer does not state otherwise, the maximum permissible
deviation from the horizontal is 3_. Greater deviations from the hori

zontal overload the slewing gear for the placing boom as well as its
overall support structure, jeopardising the stability of the machine.

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Check stability regularly during operation. The elastic distortions to

the machine frame occasionally occurring under extreme positions
of the placing boom (one support foot lifts from the ground) must be
compensated for by resetting the support cylinders until all support
feet are firmly placed on the ground.

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2.11.5 Driving 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 se

cured.
− 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 may not be exceeded.

While the vehicle is being driven, the delivery line, pump and hopper
must be empty. If there are concrete leavings in the hopper, it must
not be possible for the leavings to be thrown out while the vehicle is
in motion, thereby creating a risk of injury. You must adapt your driv

ing style to the altered centre of gravity of the machine. Observe the
road traffic regulations and specifications of the machine manufac

turer.

Maintain a clearance of at least 1m from the secured edges of con

struction pits and at least 2m from slopes.

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Always make sure that there is sufficient clearance when driving

under underpasses, over bridges and through tunnels or when pas

sing under overhead cables. The same minimum clearances apply
when driving under high−voltage lines as when working with the
placing boom. Be aware of the height of the truck. Only drive over
arches, bridges or other supporting structures if the loadbearing ca

pacity is adequate.

Do not drive across uphill or downhill gradients. Be aware of the el

evated position of the truck’s centre of gravity when travelling on a
slope and on ascending or descending routes. Always adapt your
travelling speed to the prevailing conditions on sloping terrain. Never
change to a lower gear on a slope but always before reaching it.

Observe national road traffic regulations. If necessary, clean the

tyres, lights and number plate. Before travelling with the machine,
check that the braking, steering, signalling and lighting systems are
fully functional.

Persons accompanying the driver must be seated on the passenger

seats provided for this purpose.

Whilst the truck is in motion, the mixer drum on truck mixer concrete
pumps must only be rotated at the maximum speed of rotation speci

fied in the Operating Instructions. The truck is at risk of tipping over,
particularly when travelling round corners.

2.11.6 Towing The machine must only be towed, loaded and transported in accord

ance with the Operating Instructions. Only use existing towing
hitches for towing and observe the truck manufacturer’s regulations.

You must comply with the prescribed driving position, permitted

speed and itinerary when towing.

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2.11.7 Loading The lifting points fitted to the machine as standard are provided for
assembly purposes only. They are not suitable for lifting the com

plete machine. The lifting points for lifting the entire machine are
specially marked.

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Use only appropriate means of transport and lifting equipment of ad

equate loadbearing capacity. Lifting equipment, lifting tackle, sup

port trestles and other auxiliary equipment must be reliable and safe
in operation.

Use only stable loading ramps of adequate loadbearing capacity for

loading. Ensure that no−one is at risk from the machine tipping over
or slipping.

Secure the machine against rolling, slipping and toppling over on the
transport vehicle.

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2.12 Placing booms

2.12.1 Unfolding the placing Only raise a mobile placing boom from the driving position once the
boom machine has been supported in accordance with the Operating In

structions. Stationary booms may only be raised after the proper
set−up has been checked by a subject expert.

Only raise the placing boom in the sequence described in the Oper

ating Instructions. The correct sequence depends on the folding sys

tem (roll−and−fold system, Z−fold system, etc.).

Do not carry out more than one movement at a time. If a movement is

stopped, the entire volume of fluid is available for the remaining
movements, and can increase their speeds. Depending on the de

sign, it may be the case that carrying out several movements at once
(as opposed to carrying out a single movement at maximum speed
at any one time) does not bring any advantage in terms of time.
Carrying out several movements at once requires an increased level
of attentiveness.

The range of a radio remote control is great enough for the machine
to receive control commands (e.g. from a great distance, from inside
enclosed spaces), even without visual contact. If there is no visual
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, signallers MUST
be used, and must remain in contact with the machine operator
using suitable means, and have visual contact with the site of con

crete placement, work areas and danger zones, and the machine.

Always ask the site management to provide you with an assistant to

act as a signaller. Agree clear hand signals or other signals with the
signaller so that you can communicate with each other. You should
position the signaller such that he can always observe the whole of
the placing boom. Your primary duty as the machine operator is to
observe the site of concrete placement.

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

Press the EMERGENCY STOP button immediately if the placing

boom moves unexpectedly. If this should occur, you must cease
working and have the cause of the fault rectified by your qualified
personnel or our After Sales Department.

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Placing booms with placing boom hinges which allow considerable

flex angles have a very large potential working area. This high ma

noeuvrability means different placing booms can also be moved into
dangerous positions. Prohibited areas can be found in the Operating
Instructions.

There is a risk that you will damage the truck, truck superstructure or
obstacles on the construction site with the placing boom. Under cer

tain circumstances it is even possible to overload or cause damage
to the placing boom. Uncontrolled movements may result from the
sudden, violent release of the placing boom after collisions. This may
also result in (possibly fatal) personal injury.

The manufacturer has indicated such impermissible working areas

by the use of warning signs and information plates on the machine
and appropriate notes in the Operating Instructions.

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2.12.2 Guiding the end hose The end hose must hang freely each time you start pumping, when
you start pumping again after blockages, and during washing out
procedures. No
one should stand within the danger zone of the end
hose. The diameter of the danger zone is twice the end hose length.
Do not guide the end hose when pumping is started. There is a risk
of injury from the end hose swinging out or stones being ejected.

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If a longer end hose is used, the diameter of the danger zone is also
increased (see also page212).

End hoses with a length of more than 4m must not be guided by
hand.

There is a risk of injury to the hoseman if the end hose becomes

caught in the reinforcement and suddenly jumps out on further
movement of the placing boom.

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Never bend the end hose over. Never attempt to straighten a bent
end hose by increasing the pressure. The end hose must not be sub

merged 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 presence
of air in the delivery line. To prevent this from occurring, the hopper
must be filled with concrete at least as far as the agitator shaft so
that no air can be sucked in.

The end hose must be secured against falling.

2.12.3 Guiding the end hose The hoseman must guide the end hose in such a way that prevents
ergonomically excess 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 end
hose without power consumption. The hoseman must not carry the
end hose by hand, because the weight of it may cause permanent
personal injury.

2.12.4 Connecting drills If a drill is connected to the delivery line for the placing boom, it must
not place any further strain on the placing boom. The placing boom
must be connected to the drill in such a way that the placing boom
does not require adjustment. There should be 1−2 delivery hoses be

tween the placing boom and the drill; these must be secured so that
they cannot move in an uncontrolled manner. If the drill is moved on
the construction site, the placing boom must not be connected.

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2.12.5 Procedure in storms Return the placing boom to the driving position in the event of storms
or bad weather.
− Placing booms with a vertical reach of 42m or more must only be
operated in winds of up to wind force 7 (wind speed51 km/h).
− Placing booms with a vertical reach of less than 42m may only be
operated in winds of up to wind force8 (wind speed74 km/h).

Wind speeds in accordance with the Beaufort scale are average

wind speeds measured over a period of 10 minutes. Higher speed
gusts of wind may occur briefly during the measuring period.
Higher wind speeds jeopardize stability and safety of the structural
elements. There is a risk of lightning strike in a thunderstorm.

A lightning strike poses a lethal danger to persons. The machine and

the surrounding area will be charged with electricity. Earthing the
machine does not reduce this risk. For this reason, you should fold in
the placing boom if there is a risk of lightning strike.

Tower cranes on construction sites generally have wind speed

measuring equipment, so that you can ask about the wind speed at
any time. If no wind speed measuring equipment is available, you
can ask the nearest meteorological office what the wind speed is, or
estimate the wind speed using the following rule of thumb.
− In winds of force7 and greater, green leaves break from the trees
and there is perceptible resistance when walking against the wind.
− In winds of force8 and greater, small branches break from trees
and walking outside is significantly impeded.

2.12.6 Concreting in cold The boom must not be used in temperatures below minus 15_C
weather (+5_F) unless the manufacturer has given express approval. There
is a danger of damage to the steel (brittle fracture) and the seals
throughout the system at such extreme minus temperatures.

In addition, such minus temperatures should be considered the real

istic lower limit for concrete placement, as it is no longer possible to
prepare concrete such that it can achieve its strength without the use
of special additives.

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2.13 Delivery line systems

2.13.1 Suitable delivery lines Use only 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 to
wear which varies according to the pressure and composition of the
concrete, the material from which the delivery line is made, etc.

2.13.2 Securing delivery Delivery lines, delivery hoses, end hoses and couplings must be se

lines curely fastened and secured against spontaneous opening.

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2.13.3 Tightness and block- Regularly force water through the delivery line under operating pres

ages sure to check that the system is watertight.

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A properly−cleaned delivery line is the best insurance against the

formation of blockages. Blockages increase the risk of accidents.
Never attempt to push through a blockage (e.g. by increasing the
delivery pressure, using compressed air, etc.). There is a risk of fatal
injury from the delivery line bursting or from concrete being ejected
from the end of the delivery line.

Prevent blockages by adjusting the operating conditions. Remove

blockages by reverse pumping and then restarting forward pumping.
Repeat this process several times if necessary. If the blockage is not
removed, relieve the pressure on the delivery line before removing
the section of delivery line concerned.

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2.13.4 Opening delivery lines 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 delivery
line is opened. Never work bending directly over the coupling.

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2.13.5 Clearance to delivery No−one should remain in the vicinity of separate delivery lines during
lines pumping operations. Cordon off the danger zone. If it is not possible
to place a large enough cordon around the danger zone, the deliv

ery line must be covered by suitable means.

2.13.6 Fastening delivery Delivery lines, in particular riser lines which are not laid along plac

lines ing booms, must be securely fastened in order to transfer the forces
generated in them into the structure or other structural members. The
lines must be laid so as to avoid kinks, sharp bends, stresses and
damage during pumping operations.

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2.13.7 Continuation delivery If a continuation delivery line is connected to the placing boom, it
lines must not place any further strain on the placing boom.

While you connect, use and disconnect a continuation delivery line,

you must switch off the arm assembly control system to prevent unin

tended movements of the arm assembly. There is a risk of accident
posed by jerky movements of the boom tip.

2.13.8 Devices for shutting– During operation there is a risk of being crushed and of injury by
off, diverting or clean- shearing. Hydraulically driven devices are generally supplied with
ing delivery lines power by a machine’s hydraulic system. It must therefore be poss

ible to see from the devices and the machine with control unit and
vice versa. Observe the Safety Manual for the machine and the de

vice when connecting and operating a device. Make sure that no−
one is in the danger zone before operating devices.

Use only suitable, perfectly functioning devices to shut−off, divert

and clean the delivery line. Defective and unsuitable devices may
cause damage to the whole delivery system and injure persons in
the surrounding area due to a malfunction.

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2.14 Pumping operations

2.14.1 Place of work The machine operator’s place of work is with the remote control when
the pump is in operation. If you operate the machine using the re

mote control, all operating and control devices on the machine must
be closed to prevent unauthorized interventions.

In the case of stationary placing booms, platforms or similar equip

ment are only provided for assembly and maintenance work. Use of
these platforms as a workplace during operation is prohibited.

It is forbidden to climb onto the machine during operation. In the

case of stationary placing booms, it is forbidden to climb ladders
during operation.

2.14.2 Safety Before switching on or restarting the machine or individual machine

functions, you must ensure that doing so will not endanger anyone’s
safety.

Refrain from any procedures that may impair the stability of the ma

chine or are prejudicial to safety in any other way.

2.14.3 Remote control You must always carry the remote control on your person when the
machine is ready for operation. Only in this way can it be guaranteed
that you can press the EMERGENCY STOP button in the event of an
emergency situation. The EMERGENCY STOP button may only 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 drawn
away from the machine (particularly when changing workplace), 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 against unintended
movements and unauthorized use. Switch off the remote control and
lock it away.

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2.14.4 Moving machine com- Keep all access covers, maintenance flaps, guards, etc. closed and
ponents and hot sur- locked during operation. This also applies in particular to the grille,
faces water box cover and covers over cylinders. There is otherwise a risk
of injury from moving parts of the machine and a risk of burning on
hot surfaces. In particular, there is a risk of burns from the engine,
attached parts and the exhaust.

Never start work unless the grille is closed and bolted down or other

wise secured.

Do not touch moving parts of the machine, whether the machine is

running or switched off. Always switch off the engine first, and dump
the accumulator pressure where an accumulator is fitted.

Never poke any objects (e.g. a shovel handle, trowel or similar) into
moving machine components. Such objects could become trapped
and dragged into the machine. They might then hit you or be torn
from your hands and cause you injury.

2.14.5 Constant observation You should be constantly observing the machine for any damage or
of the machine faults while it is in use. In the event of faults or malfunctions that im

pair safety at work, shut the machine down immediately and secure
it. Have the faults rectified immediately. If it is not possible to rectify
faults which jeopardize the safe operation of the machine, you must
suspend operations until the defects are rectified.

2.14.6 Truck mixer As the machine operator, it is your role to instruct the truck mixer
drivers who deliver the concrete to you, so that they are able to oper

ate the operating elements on the concrete pump provided for their
use. Only allow the truck mixer drivers to work alone once you are
certain that they have understood your instructions.

Make sure that no−one stands between the approaching truck mixer
and the machine. There is a danger of being crushed between the
truck mixer and the machine.

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2.15 Cleaning

2.15.1 General You must drain the delivery line, pump and hopper completely. Con

crete leavings in the hopper, in particular, may be thrown out whilst
the truck is moving.

The machine must not be driven with the placing boom unfolded or
the support legs extended, even over short distances. This rule also
applies when you have to drive the machine to a different site for
cleaning. The placing boom and support legs must be fully retracted
and secured.

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The preferred methods for cleaning the delivery line are reverse
pumping or forced cleaning with water. The agitator must be
switched on during reverse pumping. Otherwise, the concrete flow

ing back into the hopper can bend the agitator shaft. Use a catch
basket, pipe cleaning head and wash−out ball for forced cleaning to
prevent 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. This
causes significant corrosion damage to the electrical system.

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There is a risk of injury at all points on the machine from slipping,

tripping, bumping into things, etc. Use the handles and steps to
climb into and out of the machine. It is forbidden to stand on the
grille. 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 the
outlet on the bottom of the hopper. Do not remove the grille.

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

2.15.2 Cleaning agents Take care when using aggressive cleaning agents. Aggressive
cleaning agents may attack materials (e.g. rubber) and painted sur

faces. You can use commercially available paint cleaning and care
agents, as long as these have a pH value of between 4 and 9. Ask
the 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.

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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

danger of fire.

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2.15.3 Cleaning with com- When the delivery line is being cleaned with compressed air, there is
pressed air an increased risk of accidents caused by compressed air escaping
explosively, spurting concrete, and delivery or end hoses moving
uncontrollably if they have not been removed.

Compressed air should only be used for cleaning purposes under

the supervision of a subject expert. All persons participating in the
cleaning 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 rules
without fail:
− Individual pipes and short pipe runs up to 10m in length must not
be blown through with compressed air. There is a risk of accident
from rebound.
− Only blow out delivery lines which have the same nominal diam

eter throughout their length. Reducer pipes must be drained and
flushed out by hand.
− No bends, delivery or end hoses may be fitted at the end of the
delivery line.
− A catch basket must be fastened at the end of the delivery line
and a wash−out adaptor must be fitted on the head of the delivery
line. Catch basket and wash−out adaptor must fit the delivery line
system.
− 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 3m around the delivery
line, at the end of the delivery line and especially in front of the
opening 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 any
damage.
− Separate delivery lines that are cleaned with compressed air must
be securely fastened so that they cannot move uncontrollably.
− If continuing distribution systems (e.g. rotary distributors), gate
valves or other delivery line elements are connected to the deliv

ery line, they must be secured in such a way that they cannot
move uncontrollably.

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− The wash−out adaptor must be fitted with a separate, large dump

cock and a pressure gauge.
− The pressure gauge must be kept under constant observation dur

ing the cleaning process. The pressure in the delivery line must be
rapidly dumped via the dump cock in the event of a sudden drop
in pressure (concrete column exiting from the end of the line) or
increase in pressure (risk of blockage).
− The sponge ball or the plug used to push the concrete out must
be sufficiently dense that the air does not pass through it into the
concrete. In addition, the delivery line must be sealed to the rear
when the sponge ball or plug is caught in the catch basket.
− Only work on the delivery line (particularly when opening the deliv

ery 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 can
be injured by concrete residue that might be expelled from the
dump cock.

2.15.4 Protection against Water spraying on the machine from random directions has no dam

water aging effect. The electrical system is protected against spray water,
but is not waterproof.

You must close/seal all openings into which water/steam/cleaning

agent must not penetrate for safety or functional reasons before
cleaning the machine with water or a steam jet (high−pressure
cleaner) or other cleaning agents. Electric motors and control cabi

nets are particularly at risk.

2.15.5 Post–cleaning pro- After the machine is cleaned, the covers/tapes must be completely
cedure removed and the machine must be checked to ensure that it is ready
for operation (see also page220).

Look out for leaks, loose connections, chafe marks and damage dur

ing the cleaning procedure. Any identified defects must be rectified
immediately. The machine must be greased after it has been
cleaned using a high−pressure cleaner.

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2.16 Requirements for In the capacity of operator, it is your responsibility to provide all the
special work necessary information to the personnel concerned before special
work 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 comply

with intervals specified in the Operating Instructions, including spec

ifications for the replacement of parts and equipment. These acti

vities must be carried out by qualified personnel only.

Workshop equipment appropriate to the task in hand is absolutely

necessary for the execution of maintenance work.

Secure a wide area around the maintenance area as far as is

necessary.

A machine completely shut down for maintenance and repair work

must 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 level

and sufficiently supporting ground and is secured against rolling
away.

Use specially designed or otherwise safety−oriented climbing aids

and working platforms when carrying out assembly work above head
height. Never use machine parts as climbing aids. Keep all hand

grips, steps, railings, working platforms and ladders free from dirt,
snow and ice.

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Carefully secure individual parts and large assemblies to lifting gear

when carrying out a replacement operation. Use only suitable and
technically perfect lifting gear and suspension systems with ad

equate lifting capacity. Never stand under suspended loads.

The fastening of loads and instruction of crane operators should be

entrusted to experienced persons only. The signaller must be within
visual 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 carried

out by qualified personnel trained for such work.

Clean the machine, especially connections and threaded unions, of

any traces of oil, fuel or preservatives before carrying out mainten

ance or repair work. Do not use aggressive cleaning agents. Use
lint−free cleaning rags.

Bolted connections that you have loosened for carrying out mainten

ance and repair work must always be retightened to the specified
torque.

Do not open gas−filled spring elements, as used on maintenance

flaps, for instance. The spring elements are filled with gas under high
pressure which can escape explosively if you attempt to open them.
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 are
disposed of safely and with minimum environmental impact.

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2.17 Welding Only qualified personnel commissioned by the manufacturer may

carry out welding work on the placing boom, on the supports or on
other components which are important for safe operation. The work
must be inspected by an authorized inspector.

Always attach the earth cable of the welding unit directly to the com

ponent which is being welded. The welding current must not flow
through hinges, cylinders, etc. Significant damage may be caused in
the event of a flash over.

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Electronic components can be destroyed by stray voltage during arc

welding 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.

Only carry out welding, flame cutting and grinding operations on the
machine if this is expressly approved by the manufacturer.

Clean the machine and its surroundings of dust and flammable sub

stances and make sure that the premises are adequately ventilated
before carrying out welding, flame
cutting and grinding operations
(danger of explosion).

Only qualified personnel should carry out welding work on the fuel
and oil reservoirs in accordance with the manufacturer’s specifica

tions.

252 BP03_076_1601EN
 Safetyregulations

2.18 Working on the plac- Only carry out maintenance and repair work on the placing boom if
ing boom the placing boom is folded or properly supported, the engine is
switched 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 boom
in the driving position and can only be replaced without difficulty in
this condition. Stresses may be generated on folding if the delivery
line is replaced when the placing boom is unfolded.

Do not remove the whole delivery line but exchange the delivery
arm, e.g boom arm by boom arm. Otherwise, the pivot points of the
new delivery line will have to be redetermined using special equip

ment.

Following substantial changes, placing booms must be inspected by

an authorized inspector before recommissioning.

2.19 Safety-relevant com- Some of the manufacturer’s spare parts, such as pumps, valves and
ponents controller cards are supplied from the works with a basic setting.
These must be adjusted (set) in accordance with the information on
the circuit diagram or machine card after installation in the machine.

Parts relevant to safety and adjustable devices (pressure limiting

valve, potentiometer, fluid flow limiter, hydraulic cylinders, etc.) must
only be repaired, replaced or adjusted by After Sales Service per

sonnel. Seals must only be removed by the manufacturer’s After
Sales Service personnel. Modifications to the machine data (in par

ticular, increasing pressures, modifying speeds, etc.) are not per

mitted.

BP03_076_1601EN 253
 Safetyregulations

2.20 Software If a machine is equipped with software, the software may only be
used as is provided for in the manufacturer’s Operating Instructions.

Only persons authorized by the manufacturer may intervene in the

machine’s software. This also applies to updates.

Unauthorized interventions in the machine’s software may lead to se

vere damage and accidents.

2.21 Protective and safety Any safety equipment removed for maintenance purposes must be
equipment refitted and checked immediately upon completion of this work.

All equipment required for safety and accident prevention (warning

signs 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 signs

and information plates that have been damaged or rendered illegible
are replaced without delay.

254 BP03_076_1601EN
 Safetyregulations

2.22 Electrical power

2.22.1 General Work on electrical systems or operating equipment must only be car

ried out by qualified personnel. For further information on machines
operated on the site power supply, see also section2.22.3, entitled
power at the construction site

Machine components which are to undergo maintenance work must

be de
energized. Ensure that disconnected machine components
cannot be restarted. First of all, you must check that de
energized
parts are indeed de
energized, then earth and short
circuit them and
isolate adjacent live parts.

Disconnect the negative lead from the battery before starting any
work 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 cutting the

power supply, you must connect the supply cable to earth and short

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 second

person is required who can switch off the power supply to the ma

chine in the event of an emergency. Secure the working area with a
red−and−white safety chain and a warning plate. Use insulated tools
only.

BP03_076_1601EN 255
 Safetyregulations

2.22.2 Electrical components Control cabinet, motor and control elements are protected as stan

dard at least to degree of protection IP54. IP54 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 shall not
have a damaging effect.

Use only original fuses with the specified current rating. The electri

cal system can be destroyed by overrated fuses or bridging. You
must switch off the machine immediately if a fault occurs in the
power supply.

2.22.3 Power at the con- The power on the construction site must be supplied from a special
struction site feed point (construction site power distribution point). Machines with
an electric motor must not be connected to the mains power supply.

Only qualified personnel may work on electrical systems with an op

erating voltage in excess of 25volts alternating voltage or 60volts
direct current. Only such qualified personnel may 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 other
electrical cables if the electrical connection has not been made
properly or the supply cable is damaged.

256 BP03_076_1601EN
 Safetyregulations

2.23 Hydraulic systems

2.23.1 General Work on hydraulic systems must only be carried out by qualified per

sonnel.

Always wear your personal protective equipment when carrying out

work on the hydraulic system. Escaping fluid is toxic and can pen

etrate the skin.

Injection through the skin is a major medical emergency situation. In

the event of injuries caused by pressurized fluid, inform the company
medical officer and call a medical specialist immediately. This also
applies for injuries which may seem only slight. Hydraulic fluid which
has penetrated underneath the skin must be removed immediately.
Otherwise, there is a risk of life−endangering impairment to blood
circulation and infections.

Parts of the system and pressure lines which are to be opened (hy

draulic, pneumatic, and delivery lines) must be depressurized ac

cording to assembly descriptions before repair work is started.

Work only on depressurized systems. Switch the hydraulic pump

drive and the engine off, otherwise there is a risk of injury caused by
functional fluids escaping under pressure. Where a hydraulic accu

mulator is fitted, open the accumulator dump valve to prevent any
movements of the machine as a result of the residual pressure.
Modifications to the hydraulic accumulator are prohibited.

Be aware that enclosed hydraulic fluid can remain under pressure

for a certain length of time. Do not open any hydraulic systems if
they are under load from an external force (particularly from a raised
placing boom).

Route and install hydraulic lines in accordance with current engin

eering standards. Ensure that connections are not interchanged. The
fittings, lengths and quality of the hoses must comply with technical
requirements.

BP03_076_1601EN 257
 Safetyregulations

You must carefully bleed the hydraulic system after any maintenance
work, otherwise there is a risk of injury caused by swinging and tele

scopic support legs extending rapidly, the placing boom lowering,
etc. Open vent valves very carefully until hydraulic fluid starts to es

cape. You should on no account open vent valves further than
necessary or go so far as to remove them.

Damaged hydraulic lines must be replaced rather than repaired. You

must replace damaged or saturated hydraulic hoses immediately.
Spurting hydraulic fluid may cause injury and fire.

2.23.2 Replacing hydraulic During retesting, hydraulic hoses must be checked by a subject ex

hoses pert for outer damage. The retest must be recorded in the check
book. The operator must have hydraulic hoses replaced if they show
signs of external damage.

2.24 Noise emissions The place of work in normal operation is with the remote control. For
this reason, it is not possible to specify a particular place of work for
the machine operator. Take the values for the sound pressure level
and sound power level from the machine Operating Instructions.

Wear suitable personal protective equipment in the vicinity of the ma

chine.

As the operator, you must instruct your personnel to always wear

their personal ear protection. You are responsible for ensuring that
your personnel comply with this regulation.

All soundproofing equipment must be fitted and in perfect condition.

All soundproofing equipment must be closed during operation. A
high sound level can cause permanent hearing damage.

258 BP03_076_1601EN
 Safetyregulations

2.25 Exhaust fumes Vehicle exhaust gases contain constituents which can be lethal or
carcinogenic. Operate internal combustion engines and fuel−oper

ated heating systems only in adequately ventilated premises. Before
starting up the engine in enclosed spaces, make sure that there is
adequate ventilation and direct the exhaust gases away from the
place of work.

Wear personal protective clothing and equipment for all work in

which exhaust gases or particles of building material can enter the
body through the respiratory passages. Comply with the information
issued by the manufacturer of the building material.

2.26 Functional fluids When handling oils, greases and other functional fluids, observe the
Safety Manual applicable to the product concerned (see the safety
data sheet).

Oils, fuel and other functional fluids may be hazardous to health

upon contact with the skin, etc. You must, therefore, always wear
personal protective clothing and equipment when you are handling
toxic, caustic or other functional fluids that are hazardous to health
and always take note of the manufacturer’s information.

wz0146

Take care when handling toxic and caustic functional fluids (brake
fluid, battery acid, water glass, concrete set accelerating admix

tures, cement, etc.). Building materials containing cement have a
highly alkaline effect when they react with water (and also with per

spiration). Admixtures are toxic and caustic.

BP03_076_1601EN 259
 Safetyregulations

Cleaning agents, concrete release agents, preserving agents etc.

propelled by compressed air can cause very serious damage to the
respiratory tract if a respiratory protection mask is not worn. Spray
mist enters the lungs very easily.

Frequent injuries are eye injuries caused by concrete spatter, water

glass or other chemical substances.

Take care when handling hot functional fluids and consumables (risk
of burning or scalding).

Have used operating equipment and functional fluids such as filters,

batteries, oil, brake fluid, etc. disposed of properly. Used cleaning
rags should also be disposed of properly.

wz0186

2.27 Disposal of the ma- To dispose of the machine, you must proceed in accordance with all
chine points in the disposal regulations which apply in your country. During
the disposal operation, you must observe the following in particular:
− Remove the functional fluids, particularly hydraulic fluids, engine
oils, fuel, brake fluid, concrete admixtures, any environmentally
hazardous functional fluids or functional fluids which are hazard

ous in any other way, and dispose of these correctly.
− Remove the operating equipment, particularly the hydraulic fluid
reservoir, hydraulic cylinder, hydraulic fluid radiator, hydraulic lines
and hoses and other components which may contain residual
functional 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.

260 BP03_076_1601EN
 3 General technical description

This chapter describes the components and assemblies on this

machine and describes how they function. Please note that available
options will also be described. The machine card will tell you
whether the option described is fitted to your machine.

BP02_001_0302EN
 Generaltechnicaldescription

3.1 Overview Below you will find an overview of the most important components;
these will then be described on the following pages.
Left-hand side

1 2 3 4 5 6 7

12 11 9 10 9 8
AP21_050_1603EN 1

Pos.0 Component Page

1 Documentation accompanying the machine −
2 Engine −
3 Hydraulic pumps −
4 Pressure filter 377
5 Hydraulic fluid reservoir −
6 Fuel tank −
7 Vibrator 380
8 Pressure connection −
9 Support foot on the drawbar −
10 Centralized lubrication system (optional) 318
11 Support wheel −
12 Towing ring −

AP21_050_1603EN 31
 Generaltechnicaldescription

Right-hand side

1 2 3 4

9 8 7 6 5
AP21_050_1603EN 2

Pos.0 Component Page

1 Output controller 375
2 OPS/SPC control cabinet 321
3 Magnetic switch distributor casing 369
4 Cable remote control 363
5 Machine rating plate 37
6 Battery −
7 Fuse box 362
Control block −
8 Drive cylinder emergency control lever 376
Transfer tube emergency control lever 376
9 Agitator safety cutout (RSA) 367

32 AP21_050_1603EN
 Generaltechnicaldescription

3.2 Safety equipment This illustration shows examples of safety equipment which may be
fitted on the machine.

1 2 3 4 5

13 12 11 10 9 8 7 6
AP02_330_0904EN 1

No. 0 Safety equipment

1 EMERGENCY STOP button / STOP button on the remote control
2 Covers over the switch cylinders
3 Side protection doors
4 Exhaust guard
5 Safety grille on the V−belt
6 Transport protection
7 Securing bolts/spring pins on the support leg
8 Hydraulic/mechanical set−up foot
9 Water box cover
10 Toggle switch for Local control − 0 − Remote control
11 EMERGENCY STOP button on the operator’s side
12 Engine stop
13 Agitator safety cutout
→

AP02_330_0904EN 33
 Generaltechnicaldescription

14

15

16

AP02_330_0904EN 2

Continued
No. Safety equipment
14 Sound proofing equipment/sound proofing kit
15 Spray guard
16 Grille on the hopper

Danger
Never operate the machine if the safety equipment is not working.
Youcould injure yourself or others or damage the machine.

Check the safety equipment as described in the Operating Instructions.

34 AP02_330_0904EN
 Generaltechnicaldescription

3.3 Technical data You will find the most important technical data and setting values for
your machine in the following table, and also in the test reading de

livered with your machine and on its rating plate.

BSA model 1005 D3B C

Height 1975 mm
Dimensions Length 4270 mm
Width 1750 mm
Hydraulic drive cylinder Ø [mm] Option Mass–produced
80x45 110x63

Performance data
Main pump hydraulic fluid pressure 280 bar 280 bar
Maximum concrete pressure − rod side − bar 70 bar
Maximum concrete pressure − piston side 55 bar − bar
Maximum output rate − rod side − m3/h 52 m3/h
Maximum output rate − piston side 70 m3/h − m3/h
Maximum/minimum theoretical strokes under no
− 1/min 34 1/min
load − rod side
Maximum theoretical strokes/min under no load −
46 1/min − 1/min
piston side
Control voltage 12 V 12 V

Settings
Hydraulic fluid cut−out temperature 90 _C

Capacities
Hydraulic fluid reservoir 65 litres
Fuel tank 130 litres

AP02_935_1511EN 35
 Generaltechnicaldescription

3.3.1 Electromagnetic com- The certificate of compliance with EMC protection requirements has
patibility (EMC) been issued in accordance with Article 6 paragraph 2 of Council Di

rective 2004/108/EC on the approximation of the laws of the member
states relating to electromagnetic compatibility, implemented in Ger

many by the law concerning the electromagnetic compatibility of
equipment, dated 26th February 2008 (EMVG, section 4).

Customer: PutzmeisterAG
Max−Eyth−Strasse10
72631Aichtal, Germany
To be inspected: Concrete pump control system with
ZMS−EPS
Test location: EMCtech GmbH, Waiblingen,
Absorberhalle
Test report no.: P060556a
Date of testing: 31st March 2009

Inspection type Individual tests Basic standard System Requirement Result

Emission − ra
Radio interference field intensity EN 13309:2000 30 − 1000 MHz Broadband − A.1 passed
diated interfer
Narrow band A.3
ence (SA)
EN 13309:2000
Immunity − in
RF field, AM − modulated ISO 11451−2 20 − 1000 MHz 30 V/m Peak = passed
terference re
17 V/m + AM
sistance (SF) 80%/1kHz
13309 2000
EN 13309:2000
Vehicle voltage pulses ISO 7637−2 1, 2, 3a, 3b Degree of sever
passed
on cable remote control ity I
Function status
A
Electrostatic discharge (ESD) ISO TR 10605 Criterion B
a) direct contact a) 4 kV a) passed
b) direct air b) 4 kV b) passed

Compliance with the fundamental requirements of the EMC Directive

was confirmed on the basis of the documentation described in test
report no. P060556a. The inspections carried out with regard to ra

diated interference and interference resistance were passed.

36 AP02_754_1003EN
 Generaltechnicaldescription

3.3.2 Machine rating plate The following rating plate is attached to the machine:

1 Betonpumpe
2 BSA 1005 D3B C

3
210109379
4 6

7 8

BP22_830_1005EN 1

No. 0 Designation
1 Designation of the machine
2 Machine model
3 Machine number
4 Maximum fluid pressure in the hydraulic system [bar]
5 Year of manufacture
6 Maximum delivery pressure [bar]
The following data depend on the machine model
7 Total weight [kg]
8 Delivery line diameter [mm]

Note
If specific details do not apply to a machine, the relevant fields are
blank. With truckmounted concrete pumps, the weight specified
bythe vehicle manufacture applies as per 76/114/EEC:
"Official permitted total weight specified by manufacturer".

BP22_830_1005EN 37
 Generaltechnicaldescription

3.3.3 Sound pressure level The sound pressure level produced by the machine is given below in
accordance with Directive 2006/42/EU.

The place of work is from the remote control. The machine has a
sound pressure level of 85 dB(A) within a radius of 16m. Ear de

fenders must be worn in the vicinity of the machine since the sound
pressure level can be higher. The sound pressure was determined
on the basis of Directive 2000/14/EU.

3.3.4 Sound power level The sound power level produced by the machine is given below in
accordance with Directive 2000/14/EU.

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

116
BP21_359_1001EN 1

No. 0 Designation
LWA Sound power level
dB Value in decibels

38 BP21_359_1001EN
 Generaltechnicaldescription

What does this mean? A uniform method of measuring the noise generated by a machine
(Directive 2000/14/EU) has been applicable throughout Europe since
1January 2002.

Sound pressure level In the past, the sound pressure level of the machine was stated. To
measure this level, the sound produced by the machine was
measured at several measuring points and at a fixed distance and
height. The average value was determined from these measure

ments and converted to a theoretical distance. The sound pressure
level stated for the machine therefore always referred to a theoretical
distance and was given in dB(A).

Disadvantage: the actual sound pressure level is higher if you stand

closer to the machine.

Sound power level Nowadays, the sound power level of the machine is stated. To calcu

late this, an imaginary sphere of defined diameter is centered on the
machine. The sound pressure level is measured again at several
measuring points on this sphere. To obtain the value for the sound
power level, the calculated sound pressure level is now multiplied by
the surface area of the imaginary sphere. The sound power level is
given 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 same
sound power level as before.

BP21_359_1001EN 39
 Generaltechnicaldescription

3.4 Description of the This chapter is intended to help you understand the operational
functions sequences of the machine so that you can limit the field of the
machine’s applications to suitable areas and avoid errors in
operation.

3.4.1 Chassis Your machine may be mounted on different chassis models or on

astatic base structure, depending on the equipment. The chassis
model is stated on the machine card and the maximum permitted
speed is stated on the rating plate.

F 8 chassis Your machine can be towed by a tractor unit if fitted with an

F8chassis. The chassis is unbraked and is designed for a maxi

mum speed of 8km/h only. The machine may therefore only be
towed by a tractor unit on the construction site.

Note
The machine is neither equipped nor approved for travel on public
roads.

F 25 chassis Your machine can be towed by a tractor unit if fitted with an

F25chassis. The chassis is unbraked and is designed for a maxi

mum speed of 25km/h only. The machine may therefore only be
towed by a tractor unit on the construction site.

Note
The machine is neither equipped nor approved for travel on public
roads.

310 AP02_004_1211EN
 Generaltechnicaldescription

F 80 chassis The machine may travel on public highways in the same way as a
standard trailer if fitted with an F80 chassis.

Note
Trailer concrete pumps may only use public roads if properly
approved.

Crawler track Your machine can be towed by a tractor unit if fitted with a crawler
track.

Note
Observe the manufacturer’s operating and maintenance instructions.

The machine is neither equipped nor approved for travel on public

roads.

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

3.4.3 Support legs The support legs give the stability required. They are manually
adjustable.

AP02_004_1211EN 311
 Generaltechnicaldescription

3.4.4 Pump

1
2
3

6
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 or

electric motors acting through fluid pumps. The delivery pistons(3)
are connected to the piston rods(1) of the drive cylinders by way of
intermediate flanges. The drive cylinders are extended and retracted
hydraulically and thus push the delivery pistons(3) forwards and
backwards in the delivery cylinder(4). The drive cylinders are
hydraulically coupled together so that they run in counter stroke.

312 AP02_004_1211EN
 Generaltechnicaldescription

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

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

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

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

Change-over Reversal of the delivery pistons’ direction in the middle of the stroke
movement. The transfer tube switches over. The medium is still
pumped without interruption. Changing the stroke over helps prevent
the formation of a blockage.

Reverse pumping The delivery pistons reverse their direction during the stroke move

ment for reverse pumping. The transfer tube does not switch over so
the pump now runs in reverse. The medium is sucked from the deliv

ery line and pumped back into the hopper and the pressure in the
delivery line is dumped.

AP02_004_1211EN 313
 Generaltechnicaldescription

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

AP02_055_9710EN 1

No0 Designation
1 Hydraulic motor
2 Agitator shaft
3 Agitator helix

Improving the The filling rate in the delivery cylinders should be as high as possible
filling rate when pumping. This is achieved by having the agitator helix mix to

wards the delivery cylinders.

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

314 AP02_055_9710EN
 Generaltechnicaldescription

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

3.5.1 Service life If operated, maintained and inspected correctly, and if original or
equivalent spare parts and accessory components are used, the
service life is 15years.

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

Output [m3]/year 15000
Operating hours [h]/year 200
Uses per day 1
Uses per year 250

stationary concrete pump standard

Stationary boom
Delivery line valve
Output [m3]/year 20000
Operating hours [h]/year 400
Uses per day 1
Uses per year 250

BP22_827_1212EN 315
 Generaltechnicaldescription

3.5.2 Site of use A concrete pump is designed for industrial use on outdoor construc

tion sites, or indoors with adequate ventilation. It must not be used in
areas where there is a potentially explosive atmosphere.

3.5.3 Height of job Putzmeister must be contacted if the concrete pump is to be used at
a height greater than that given here. The standard reference level is
the European standard elevation zero (NHN).

Pump type maximum height

of job
Piston pump with internal combustion
engine, 2500m
Delivery line valve

Piston pump
p p with electric motor,, 1000m (v40°C)
Stationary boom 2000m (v30°C)
Rotor pump 2000m

316 BP22_827_1212EN
 Generaltechnicaldescription

3.5.4 Operating Putzmeister must be contacted if the concrete pump is to be used

temperature outside the given temperature ranges.

max
Machine model min [° C]
[° C]
Truck−mounted concrete pump,
Delivery line valve
−15
15 +50
+ 50
Truck mixer concrete pump
(with piston pump)
Stationary concrete pump with diesel
−8 +45
engine*
Stationary concrete pump with electric
motor** −8 +40
Stationary boom**
General rotor pump*** +3 +40

*Limited due to the diesel engine without pre
heating device. When

using below −8°C, a pre
heating device must be installed.
**Limited due to supply cable during overload. Temperature ranges
can be extended if special measures are applied.
***Limited due to the vacuum pump and rotor hose.

BP22_827_1212EN 317
 Generaltechnicaldescription

3.5.5 Centralized lubrica- The centralized lubrication system comprises a lubricant pump /
tion system grease gun, lubricant distributors, relief valves and supply lines.

1a

1b

3 3

6
4 4

5
7 98 7

AP02_908_1304EN 1

No. 0 Designation
1a Lubricant reservoir
1b Lubricant pump
2 Grease gun
3 Lubricant distributor
4 Agitator shaft bearings
5 Transfer tube bearing
6 Upper switch cylinder bearings
7 Lower switch cylinder bearings
8 Switching shaft bearings

318 AP02_908_1304EN
 Generaltechnicaldescription

The centralized lubrication system supplies grease to the lubrication

points connected to it. The lubrication points are lubricated in fixed
cycles.

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

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

Grease gun The grease gun can be used to manually distribute grease to the lu

brication points.

AP02_908_1304EN 319
 Generaltechnicaldescription

3.6 Electrical control The electrical control devices and operating elements on this
devices machine are described on the following pages. The summary at the
start of this chapter will show you where the various control devices
are 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

Note
Further control devices and components are described in the

Hydraulic control devices" (from page 374) and
Other
components" (from page 378) sections.

320 AP02_057_9801EN
 Generaltechnicaldescription

3.6.1 Control cabinet with You can control the functions of the machine from the control cabi

SPC display unit net.
SPC = Small Pump Control
The SPC display enables you to determine the operating state of the
machine.
Use the operating elements of the SPC display unit to navigate within
the menu structure and apply settings.
Some of the control and operating elements illustrated below may
not be present on your machine. The hole is closed with a blanking
plug if a control or operating element is omitted.

Front view
1 2

11 10 9 8 7 6 5

AP21_022_1510EN 1

Operating/
Pos. 0 Meaning/function Comments
control element
1 Button EMERGENCY STOP
2 Display unit Operating states are displayed and set in
the SPC display
3 Toggle switch Increase  reduce engine speed
4 Rotary controller Increase  reduce delivery rate optional
5 Toggle switch Support leg control optional
→

AP21_022_1510EN 321
 Generaltechnicaldescription

Continued
Operating/
Pos. 0 Meaning/function Comments
control element
6 Toggle switch Deactivate EMERGENCY STOP − 0 − Ac

knowledge agitator/agitator safety cutout
(RSA)
7 Ignition−starter switch Diesel engine On − Off
8 Toggle switch Open shut
off valve − agitator − close
shut
off valve
9 Toggle switch Agitator on  agitation direction away from
the delivery cylinder
Agitator off
Agitator on  agitation direction towards
the delivery cylinder
10 Toggle switch Pump off − 0 − Vibrator on
11 Toggle switch Forward pumping− 0− Reverse pumping

322 AP21_022_1510EN
 Generaltechnicaldescription

Right–hand view

AP21_022_1510EN 2

Operating/
Pos. 0 Meaning/function Comments
control element
1 Round socket, 4
pin Connection for vibrator optional
2 Socket Connection for remote control/
Local control − Remote control
Local control = replacement plug is
plugged in

AP21_022_1510EN 323
 Generaltechnicaldescription

SPC display unit and

operating elements

2 2 2 2

6 5 4
AP21_022_1510EN 3

Operating/
Pos. 0 Meaning/function
control element
Menu−driven operating states and adjustable functions
1 SPC display
are displayed in the SPC display.
2 Momentary
contact switch 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 the
program is running.
4 Button Function button for acknowledging
5 Direction key Function button for navigation and operation.
6 Button Function button with no function

324 AP21_022_1510EN
 Generaltechnicaldescription

Special features of the control cabinet

Starting up the pump If you have pressed the EMERGENCY STOP button, you may only
after EMERGENCY start the pump up again as described below:
STOP − 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.

Control system (OPS) The control system can control machines with an open hydraulic cir

cuit. The open hydraulic circuit is called Open Pump System (OPS).

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

Note
You can switch on the SPC display unit with the
ignition−starter
switch" on the control cabinet.

AP21_022_1510EN 325
 Generaltechnicaldescription

Forward pumping− 0− The function of the Forward pumping  0  Reverse pumping"
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 Reverse
pumping" toggle switch on the control cabinet.
− The pump can only be switched over on the cable or radio remote
control using the Pump on  0  Reverse pumping" toggle switch
for remote control.

Switchover from local to The EMERGENCY STOP circuit is activated automatically when you
remote control remove the replacement plug (remote control). You must press the
Deactivate EMERGENCY STOP" toggle switch to deactivate the
EMERGENCY STOP circuit.

Acknowledge agitator If the agitator safety cutout has been triggered, it must be acknowl

edged using the Deactivate EMERGENCY STOP  0  Acknowledge
agitator/agitator safety cutout (RSA)" toggle switch so that the agita

tor starts running again.

Locking You must always lock the control cabinet and store the key in a safe
place to ensure that unauthorized persons cannot operate the con

trol system.

326 AP21_022_1510EN
 Generaltechnicaldescription

3.6.2 SPC display unit The SPC display unit on the control cabinet has a graphical display
and operating elements. The SPC display enables you to determine
the operating state of the machine. Use the operating elements of
the SPC display unit to navigate within the menu structure and apply
settings.

SPC display unit and

operating elements

2 2 2 2

6 5 4
AP21_024_1511EN 1

Operating/
Pos. 0 Meaning/function
control element
Menu−driven operating states and adjustable functions
1 SPC display
are 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 the
program is running.
4 Button Function button for acknowledging
5 Direction key Function button for navigation and operation.
6 Button Function button with no function

AP21_024_1511EN 327
 Generaltechnicaldescription

Appearance of the The symbols used in the SPC display appear differently depending
symbols on the meaning.

Colour / Appearance Meaning

Background colours:
Black Standard appearance
Symbol colours:
White Function is selected (switch or button
pressed)
Green Function is active
Yellow Warning on the engine’s control dis

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

play:Fault
Red The fault must be remedied before
the operation can be restarted on the
machine.
Dark grey Display of inactive functions
Input field appearance:
Green Display of input fields
Set setpoint value = actual value in
the controller
− Input is possible depending on the
menu
Value has been changed, but has not
yet been acknowledged with the
Yellow OK" button
− Input is possible depending on the
menu

328 AP21_024_1511EN
 Generaltechnicaldescription

Menu structure The following pages show the password
free section of the menu
structure (example). A start screen is always displayed when the
machine is started up.

3 2

4 5 6 7

8 9

AP21_045_1602EN 1

AP21_045_1602EN 329
 Generaltechnicaldescription

Pos.0 Display Function/meaning See page

The start screen is displayed once the
1 Start screen SPCdisplay unit on the control cabinet is 331
supplied with power.
The HOME menu is the main menu. Data and
2 HOME 332
main instruments are displayed here.
Select this menu to display data and all
3 Expanded HOME 342
instruments.
Select this menu to display the software
4 Software information 345
version and firmware version.
5 Operating data Select this menu to display operating data. 346
Select this menu to display the fault codes
6 Fault memory 348
for the engine.
Select this menu to set parameters such as the
7 User settings 349
delivery rate and stroke time.
Select this menu to begin a manual lubrication
8 Lubrication cycle and display parameters such as the 353
number of strokes until the next lubrication.
Select this menu to display the number of
9 Inputs and outputs 356
active inputs and outputs.

330 AP21_045_1602EN
 Generaltechnicaldescription

Start screen The start screen in the SPC display unit is displayed for a few sec

onds once the ignition−starter switch on the control cabinet is
switched on. The SPC display goes out once the power supply or the
engine of the stationary concrete pump is switched off.

Note
Depending on the equipment fitted to your machine, some of the
functions illustrated may not be present. The symbol is not lit if a
function is not present.

AP21_026_1511EN 1

Pos.0 Display Function/meaning

The start screen is displayed once the SPC display
1 Start screen
unit on the control cabinet is supplied with power.

AP21_026_1511EN 331
 Generaltechnicaldescription

HOME menu The HOME menu is the main menu. Data and main instruments are
displayed here.

Function buttons in the HOME menu

1 2 3 4 5 6
AP21_046_1602EN 1

Pos.0 Display Function/meaning

1 Button The last selected start menu is opened by pressing button(1).
The expanded HOME menu is opened by pressing button(2)
2 Button
in the HOME menu.
Submenus are selected by pressing on the left or right of the
3 Direction key
direction button(3).
The selected submenu is acknowledged and then called up
4 Button
by pressing button(4).
The EOC" is switched on/off by pressing button(5) in the
5 Button
HOME menu.
The Stransfer tube switch
over" function is switched over
6 Button
bypressing button(6) in the HOME menu.

332 AP21_046_1602EN
 Generaltechnicaldescription

All symbols in the menu bar

1 2 3 4 5

AP21_046_1602EN 2

Pos.0 Symbol Function/meaning

Back to the start menu
1 This symbol is displayed regardless of the current menu.
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: Service
password
protected service area
→

AP21_046_1602EN 333
 Generaltechnicaldescription

Continued
Pos.0 Symbol Function/meaning

1 Switch EOC on/off

Stransfer tube switch
over:

2
Snail, hare and auto
Reset the trip" day counter
3 This symbol is displayed in the following menus:
Operating data, user settings

334 AP21_046_1602EN
 Generaltechnicaldescription

Instruments in the HOME menu

1 2 3

3
AP21_046_1602EN

Pos.0 Display Function/meaning

Cooling water temperature[°C], The cooling water temperature is displayed.
1
analogue and digital
Engine speed[rpm], The engine speed is displayed.
2
analogue and digital
Hydraulic fluid temperature[°C], The hydraulic fluid temperature is displayed.
3
analogue and digital

AP21_046_1602EN 335
 Generaltechnicaldescription

Symbols in the HOME menu

AP21_047_1602EN 1

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

336 AP21_047_1602EN
 Generaltechnicaldescription

Engine status
This symbol is displayed in grey if the engine is running properly.
This symbol is displayed in yellow = engine warning if, for example,
a limit has been reached on the engine.
This symbol is displayed in red if a fault has occurred in the engine.

Engine oil pressure

This symbol is displayed in grey if the engine oil pressure is within
the specified range.
This symbol flashes and is displayed in red if the engine oil pressure
is too low.
If the signal for the engine oil pressure is interrupted for longer than a
few seconds, the concrete pump is switched off.

Engine oil temperature

This symbol is displayed in grey if the engine oil temperature is
within 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 longer
than a few seconds, the concrete pump is switchedoff.

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

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

CAN bus engine communication CAN1

This symbol is displayed in grey if no fault has occurred in the
CANbus1.
This symbol flashes and is displayed in red if a fault has occurred in
the CANbus (CAN1 = connection between controller and display).
You need to have the fault rectified by a Putzmeister service techni

cian.

AP21_047_1602EN 337
 Generaltechnicaldescription

CAN bus engine communication CAN2

This symbol is displayed in grey if no fault has occurred in the
CANbus2.
This symbol flashes and is displayed in red if a fault has occurred
inthe CANbus (CAN2 = connection between engine control unit and
controller). You need to have the fault rectified by a Putzmeister
service technician.

Sensors
This symbol is displayed in grey if no fault has occurred in the
magnetic switches (see the Magnetic switches 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
by a Putzmeister service technician.

Hydraulic fluid overheating

This symbol is displayed in grey if the temperature sensor in the leak
oil line of the main hydraulic pump measures a temperature lower
than 85_C and no fault has occurred.
This symbol flashes and is displayed in red if the temperature sensor
in 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 will
be switched off automatically.

Battery charging control

This symbol is displayed in grey if the battery is charged.
This symbol flashes and is displayed in red if the battery voltage has
tripped out and the engine is switched off.

338 AP21_047_1602EN
 Generaltechnicaldescription

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

Agitator safety cutout (RSA)

This symbol is displayed in grey if the agitator safety cutout
hasnotbeen pressed or if the agitator safety cutout has been
acknowledged.
This symbol flashes and is displayed in red if the agitator safety
cutout has been activated.

Pump status
This symbol is displayed in grey if the concrete pump is switched
offand all pump functions (Pumpon", Forward pumping" and
Reverse pumping") either have not been operated or have been
acknowledged.
This symbol is displayed in white if the concrete pump is switched off
(when the Pumpoff− 0− Vibratoron" toggle switch has been
moved to the Pumpoff" switch position on the control cabinet).

Forward pumping
This symbol is displayed in white if the concrete pump is switched off
and the Forward pumping" pump function is operated.
This symbol is displayed in green if the concrete pump is switched
on and the Forward pumping" pump function is operated.

Reverse pumping
This symbol is displayed in white if the concrete pump is switched off
and the Reverse pumping" pump function is operated.
This symbol is displayed in green if the concrete pump is switched
on and the Reverse pumping" pump function is operated.

AP21_047_1602EN 339
 Generaltechnicaldescription

EOC
This symbol is displayed in grey if EOC is switched off.
This symbol is displayed in green if EOC is switched on.

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

S transfer tube switch-over

The Stransfer tube switch
over" function can be switched over as
follows using the button (see the Function buttons in the HOME
menu" section):
− The Stransfer tube is switched over with less force: Snail".
− The Stransfer tube is switched over with more force: Hare".
− The Stransfer tube switch
over is adjusted automatically:
auto"=factory settings after restart.

340 AP21_047_1602EN
 Generaltechnicaldescription

Vibrator
This symbol is displayed in grey if the vibrator is switched off.
This symbol is displayed in white if the concrete pump and the
vibrator are switched off but the Pumpoff− 0− Vibratoron" toggle
switch has been switched to Vibratoron" on the control cabinet with
SPC display.
This symbol is displayed in green if the vibrator is switched on.

Lubrication
This symbol is displayed in grey if no lubrication procedure has been
activated.
This symbol lights up green during the lubrication procedure.
This symbol lights up red if there is a fault or if a lubricant reservoir is
empty.

AP21_047_1602EN 341
 Generaltechnicaldescription

Expanded HOME The HOME menu is the main menu. Data and main instruments are
menu displayed here.

Function buttons in the expanded HOME menu

1 2 3 4 5 6
AP21_029_1511EN 1

Pos.0 Display Function/meaning

The last selected start menu is opened by pressing
1 Button
button(1).
The HOME menu is opened by pressing button(2) in
2 Button
the expanded HOME menu.
Submenus are selected by pressing on the left or right
3 Direction key
of the direction button(3).
The selected submenu is acknowledged and then
4 Button
called up by pressing button(4).
The EOC" is switched on/off by pressing button(5) in
5 Button
the HOME menu.
The S transfer tube switch−over" function is switched
6 Button
over by pressing button(6) in the HOME menu.

342 AP21_029_1511EN
 Generaltechnicaldescription

Instruments in the expanded HOME menu

1 2 3 4

5 6 7

AP21_029_1511EN 2

Pos.0 Display Function/meaning

Cooling water tempera
The cooling water temperature is displayed.
1
ture[°C], analogue
Engine oil pressure[bar], The engine oil pressure is displayed.
2
analogue
Engine speed[rpm], ana
The engine speed is displayed.
3
logue and digital
Hydraulic fluid tempera
The hydraulic fluid temperature is displayed.
4
ture[°C], analogue
Fuel consumption[l/h], The fuel consumption is displayed.
5
analogue
6 Torque[N/m], analogue The current torque is displayed.
Battery voltage[V], ana
The current battery voltage is displayed.
7
logue

AP21_029_1511EN 343
 Generaltechnicaldescription

All symbols in the menu bar

Note
You can find a description of all symbols in the menu bar, regardless
of the current menu, in the section
All symbols in the menu bar".

Symbols in the expanded HOME menu

AP21_029_1511EN 3

Note
You can find a description of the symbols in the expanded HOME
menu in the section
Symbols in the HOME menu".

344 AP21_029_1511EN
 Generaltechnicaldescription

Software information In this menu, you can read off the software versions of the control
systems.

Display Function/meaning
PM Putzmeister
SPC Small Pump Control
g2 Generation 2
C Controller
D Display
V100 Version 1.0.0

AP21_030_1511EN 1

Pos.0 Display Function/meaning

The software versions of the control systems are dis

1 Software versions
played.
The last selected HOME menu can be opened by
2 Momentary
contact switch
pressing button(2).

AP21_030_1511EN 345
 Generaltechnicaldescription

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

1 2

10

4 3

AP21_031_1511EN 1

Pos.0 Display Function/meaning

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

2 Trip" table
played.
The current values in the trip" table are reset after a
3 Momentary
contact switch
few seconds by pressing button(3).
The last selected HOME menu can be opened by
4 Momentary
contact switch
pressing button(4).
→

346 AP21_031_1511EN
 Generaltechnicaldescription

1 2

10

4 3

AP21_031_1511EN 2

Continued
Pos. Display Function/meaning
The current stroke time2 is displayed.
5 Stroke time2[s] Stroke time2: For example, the time required for drive
piston2 to move towards the water box.
The current stroke time1 is displayed.
6 Stroke time1[s] Stroke time1: For example, the time required for drive
piston1 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.
The current operating hours of the pump are displayed
9 Pump operating hours
in numbers.
The current operating hours of the engine are dis

10 Engine operating hours
played in numbers.

AP21_031_1511EN 347
 Generaltechnicaldescription

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

AP21_032_1511EN 1

Pos.0 Display Function/meaning

1 Fault The fault code is displayed.
The last selected HOME menu can be opened by
2 Momentary
contact switch
pressing button(2).

348 AP21_032_1511EN
 Generaltechnicaldescription

User settings In this menu, you can set setpoint values for the pump output and
the fill level of the delivery cylinders and compare them with the
actual values that have been achieved. The delivery rate can be
calculated 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 engine
speed.
If a fault has occurred in a magnetic switch or resolver, you can set a
suitable 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 value
Yellow Input has not been acknowledged

AP21_033_1511EN 349
 Generaltechnicaldescription

Function buttons in the user settings menu

1 2 3 4
AP21_033_1511EN 1

Pos.
Display Function/meaning
0

The last selected HOME menu can be opened by

1 Momentary
contact switch
pressing button(1).
Parameters are selected by pressing up or down on
the direction button(2).
2 Direction key
The value of the parameter is set by pressing left or
right on the direction button(2).
The set value for the parameter is acknowledged by
3 Momentary
contact switch
pressing button(3).
The adjustable values (pump output, fill level of the de

4 Momentary
contact switch livery cylinders, engine speed and stroke time) can be
reset to their factory settings by pressing button (4).

350 AP21_033_1511EN
 Generaltechnicaldescription

1 2

4 3

AP21_033_1511EN 2

Pos.
Display Function/meaning
0

The specified pump output or the fill level of the deliv

1 Setpoint values
ery cylinders is displayed.
The pump output or fill level of the delivery cylinders
that has been achieved is displayed.
2 Actual value (adjustable)
The two parameters are used in the calculation of the
output [m3/h].
In the event of a fault: The set stroke time or simulated engine speed is dis

3
Actual value (adjustable) played.
In the event of a fault: The specified stroke time or engine speed is dis

4
Setpoint values played.
→

AP21_033_1511EN 351
 Generaltechnicaldescription

Continued
Pos. Display Function/meaning
In the event of a fault: The setpoint and actual values for the stroke time are
5
Stroke time[s] displayed.
In the event of a fault: The simulated engine speed is displayed in numbers.
6
Engine speed[rpm], digital
Fill level of the delivery cyl
The setpoint and actual values for the Fill level of the
7
inders[%] delivery cylinders" parameter are displayed.
The setpoint and actual values for the Pump output"
8 Pump output[l]
parameter are displayed.

352 AP21_033_1511EN
 Generaltechnicaldescription

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

Function buttons in the lubrication menu

1 2 3 4 5

AP21_048_1602EN 1

Pos.0 Display Function/meaning

1 Button The last selected start menu is opened by pressing button(1).
A manual lubrication cycle is activated by pressing button(2)
2 Button
in the lubrication menu.
The number of strokes between two lubrication cycles is set
3 Direction key
by pressing on the left or right of the direction button(3).
4 Button The new setting is saved by pressing button(4).
The current settings are reset to the factory settings by
5 Button
pressing button(5).

AP21_048_1602EN 353
 Generaltechnicaldescription

All symbols in the menu bar

1 2 3

AP21_048_1602EN 2

Pos.0 Symbol Function/meaning

Back to the start menu
1 This symbol is displayed regardless of the current menu.
The symbol has no function in the HOME menu.

2 Manually activate a lubrication cycle.

3 Reset to the factory settings.

354 AP21_048_1602EN
 Generaltechnicaldescription

AP21_048_1602EN 3

Pos.0 Display Function/meaning

The number of strokes until the next lubrication is
1 Number of strokes, analogue
displayed.
The number of strokes until the next lubrication is
2 Number of strokes, digital
displayed in numbers.
The number of strokes performed since the last
3 Number of strokes, digital
lubrication is displayed in numbers.
The number of strokes between two lubrication cycles
4 Number of strokes, digital
is displayed.

AP21_048_1602EN 355
 Generaltechnicaldescription

Inputs and outputs 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 Stransfer
tube, for example after installing the resolver.

Function buttons in the inputs and outputs menu

1 2

AP21_049_1602EN 1

Pos.0 Display Function/meaning

1 Button The last selected start menu is opened by pressing button(1).
The current settings (position values for the Stransfer tube)
2 Button
are reset to the factory settings by pressing button(5).

356 AP21_049_1602EN
 Generaltechnicaldescription

All symbols in the menu bar

1 2

AP21_049_1602EN 2

Pos.0 Symbol Function/meaning

Back to the start menu
1 This symbol is displayed regardless of the current menu.
The symbol has no function in the HOME menu.
The position values for the Stransfer tube are reset to
2
the factory settings.

AP21_049_1602EN 357
 Generaltechnicaldescription

AP21_049_1602EN 3

Pos.0 Display Function/meaning

An overview of all inputs is displayed. The active
1 IN = inputs, analogue
inputs are displayed in green.
2 IN = inputs, digital The active inputs are also displayed in numbers.
An overview of all outputs is displayed. The active
3 OUT = outputs, analogue
outputs are displayed in green.

358 AP21_049_1602EN
 Generaltechnicaldescription

3.6.3 Ergonic Output Con- The Ergonic Output Control (EOC) enables you to save the selected
trol (EOC) engine speed.
You can switch the Ergonic Output Control on and off using the SPC
display unit.

HOME menu

AP21_034_1512EN 1

Pos.0 Display Function/meaning

1 Symbol: EOC

The EOC" is switched on/off by pressing button(1) in

2 Momentary
contact switch
the HOME menu.

AP21_034_1512EN 359
 Generaltechnicaldescription

Special features of Ergonic Output Control

Switch Ergonic Output If the display is malfunctioning or de−energised or a CAN bus fault
Control on/off has occurred, the Ergonic Output control will be switched on auto

matically.

If the display is functioning properly, the Ergonic Output Control will

be switched off after the control system is restarted (switching on the
ignition). The Ergonic Output Control can be subsequently switched
on/off.

Ergonic Output Control If the Ergonic Output Control is switched on, the pump control sys

switched on tem will behave in the following way:

Concrete pump start The engine will be started up at the EOC engine speed if the current
engine speed when the concrete pump is started up is smaller than
the saved EOC speed.
The engine will run with no change in speed if the current engine
speed when the concrete pump is started up is greater than or equal
to the saved EOC speed.
The engine will run with the factory−set EOC speed if no current EOC
speed has been saved.

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

Concrete pump The engine is started up at the factory−set idling speed.The engine
switched off speed that was most recently used during pumping operations will
be saved as the EOC speed.

360 AP21_034_1512EN
 Generaltechnicaldescription

Ergonic Output Control The factory−set engine speed replaces any saved EOC speed.
switched off If the Ergonic Output Control is switched off, the pump control sys

tem will behave in the following way:

Concrete pump start The engine will be started up at the factory−set engine speed if the
current engine speed when the concrete pump is started up is
smaller than the preset engine speed.
The engine will run with no change in speed if the current engine
speed when the concrete pump is started up is greater than or equal
to the factory−set engine speed.

Concrete pump The engine speed can be set using the control cabinet or the cable
switched on remote 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

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

switched off

AP21_034_1512EN 361
 Generaltechnicaldescription

3.6.4 Fuse box The fuse box is located underneath the OPS/EGD control cabinet".
The toggle switch for Engine protection override" is located at the
side on the right and can be used to continue running the engine in
emergency operation for a short time.

Front view

1 2

AP02_933_1309EN 1

No. 0 Operating/control element Meaning/function

1 Fuse box
2 Toggle switch Engine protection override

Special features of the fuse box

Emergency operation If the engine overheats, it switches off automatically (see Engine
status" symbol in the EGD of the OPS/EGD control cabinet).
Inemergency operation, the Engine protection override" switch
must be permanently held down by hand when switching on and
continuing to run the engine.

362 AP02_933_1309EN
 Generaltechnicaldescription

3.6.5 Cable remote control The most important control functions for the pump are gathered
together on the cable remote control, so that you can control the
operation of the pump from here.

1 2

4 3

AP02_905_1304EN 1

No. 0 Operating/control element Meaning/function Comments

1 Momentary
contact switch EMERGENCY STOP
2 Toggle switch Increasespeed− Reducespeed
3 Toggle switch Deactivate EMERGENCY STOP
4 Toggle switch PumpOn− 0− Reversepumping

Note
You need only press one of the EMERGENCY STOP buttons to
trigger an EMERGENCY STOP of the machine.

To release the EMERGENCY STOP condition again, you must unlock

the EMERGENCY STOP button that has been pressed by turning it.

You must press the
Deactivate EMERGENCY STOP" toggle switch

to make the pump start up once more.

AP02_905_1304EN 363
 Generaltechnicaldescription

Special features of the cable remote control

Starting up the pump The red EMERGENCY STOP activated" indicator lamp on the
after EMERGENCY control cabinet lights up and the green Pump running" indicator
STOP lamp 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.
å The red EMERGENCY STOP activated" indicator lamp on
the control cabinet goes out.
− Switch the pump on.

364 AP02_905_1304EN
 Generaltechnicaldescription

3.6.6 EMERGENCY STOP EMERGENCY STOP buttons are fitted to the following machine com

button ponents:
− the cable remote control
− the right
hand side of the machine, near the operating elements.

Caution
Familiarize yourself with the positions of the EMERGENCY STOP but
tons on your machine.

30505901

EMERGENCY STOP button

Note
You need only press one of the EMERGENCY STOP buttons to
trigger an EMERGENCY STOP of the machine.

To release the EMERGENCY STOP condition again, you must unlock

the EMERGENCY STOP button that has been pressed by turning it.

You must press the
Deactivate EMERGENCY STOP" toggle switch

to make the pump operational once more.

AP02_846_1203EN 365
 Generaltechnicaldescription

The following actions are triggered when you press one of the
EMERGENCY 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.

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

To start up the agitator again, you must actuate the
Acknowledge

agitator / agitator safety cutout" toggle switch on the control cabinet.

366 AP02_846_1203EN
 Generaltechnicaldescription

3.6.7 Agitator safety cutout The agitator safety cutout consists of a transponder and an evalu

(RSA) ation device with reading head. As soon as you open the grille, the
radio link between the transponder and reading head is broken. This
causes the agitator to halt and the pressure to be dumped from the
accumulator, i.e. the transfer tube will no longer be able to switch
over. In addition, the delivery pistons return to the end position and
the concrete pump halts. You must switch the concrete pump off and
back on again to restart it. In order that the agitator starts turning
again and the accumulator refills, you must acknowledge the agitator
safety cutout on the EPS/EGD control cabinet.

1 2

3
4

AP02_855_1202EN 1

No. 0 Designation
1 Transponder (in the grille)
2 Acknowledge agitator or agitator safety cutout
on the EPS/EGD control cabinet
3 LED, green and red
4 Reading head (on the hopper − example illustration)

AP02_855_1202EN 367
 Generaltechnicaldescription

Note
If the evaluation device becomes defective, the agitator safety cutout
is triggered and the agitator, transfer tube and concrete pump are
stopped.

Therefore, always check that the agitator safety cutout is working

properly before using the pump.

The LED on the evaluation device has the following display:

 The green LEDs flash for 8seconds during the initialization pro
cess.
 The green LEDs light up during normal operation when the grille is
closed.
 The green LEDs flash when the grille is open.
 The red LED lights up when there is a fault with the evaluation de
vice.

368 AP02_855_1202EN
 Generaltechnicaldescription

3.6.8 Magnetic switches The distributor casing for the magnetic switches is located beneath
distributor casing the control cabinet.

1 3

2 5 4
AP02_853_1202EN 1

Belongs
No. 0 Control element Meaning/Function
with no.:
1 Yellow LED Magnetic switch (rod side), drive cylinder II
2 Yellow LED Magnetic switch (rod side), drive cylinder I
3 Female connector Not assigned
4 Yellow LED Magnetic switch (piston side), drive cylinder I
5 Green LED In service lamp

AP02_853_1202EN 369
 Generaltechnicaldescription

Special features of the distributor casing

LEDs 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 magnetic
switches. The LEDs for the magnetic switches that have just been
triggered 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 despite Magnetic switch, connector or

triggering lead are defective, replace im

mediately as switchover is no
mediately,
lights up continuously longer possible

In service lamp Distributor casing status

lights up continuously The distributor casing is ready

for operation.

does not light up The Putzmeister operating sys

tem is not supplied with a volt

age.

Note
Additional LEDs are located on the magnetic switch connector (see
page 372). These LEDs indicate whether it is the magnetic switch
or the connector and lead that is defective.

370 AP02_853_1202EN
 Generaltechnicaldescription

Stroke correction Electronic stroke correction on this machine takes place as required.
As soon as the piston side magnetic switch in drive cylinder1 is trig

gered, it always resets the set time to zero. If this magnetic switch is
no longer triggered, the set time (e.g.1min) counts down. If the time
has elapsed, the rod side magnetic switch in drive cylinder2 is
cleared. This means that switchover only occurs through the piston
side magnetic switch in drive cylinder1. Once this has been trig

gered again (stroke correction has taken place), the cleared rod side
magnetic switch is reconnected and the time is reset to zero.

Note
The machine could make loud noises during stroke correction since
the hydraulic fluid is pressed through the stroke correction line at
high pressure.

AP02_853_1202EN 371
 Generaltechnicaldescription

3.6.9 Magnetic switch The connector for the magnetic switch has one yellow and one green
connector light−emitting diode. These LEDs indicate the status of the connector
and the magnetic switch.

1 2

20500406

No. 0 Designation
1 Green and yellow LEDs
2 Connector
3 Magnetic switch

Note
The yellow LED indicates the status of the magnetic switch, the
green LED indicates the status of the connector and the lead.

372 BP02_428_9707EN
 Generaltechnicaldescription

Significance of
Yellow LED Magnetic switch status
the LEDs
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 the
magnetic switch (otherwise
switchover is not possible) and
replace at earliest opportunity

Green LED Connector and lead status

lights up A voltage is being applied to the

connector, i.e. connector and
lead are in order

does not light up No voltage is being applied to

the connector, i.e. connector or
lead are defective

BP02_428_9707EN 373
 Generaltechnicaldescription

3.7 Hydraulic control The hydraulic control devices and operating elements on this
devices machine are described on the following pages. The summary at the
start of this chapter will show you where the various control devices
are located on the machine. The symbols used on the hydraulic
control devices are described in one of the preceding sections.

The hydraulic control devices may include the following components,

depending on the equipment on your machine.
− agitator lever
− water pump lever
− compressor lever
− output controller
− accumulator dump cock
− transfer tube damping cock

Note
Further control devices and components are described in the

Electrical control devices" (from page 320) and
Other
components" (from page 378) sections.

374 AP02_058_9801EN
 Generaltechnicaldescription

3.7.1 Output controller 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 concrete
pump is switched off.

AP21_010_1505EN 1

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

No. 0 Designation
1 Output controller

AP21_010_1505EN 375
 Generaltechnicaldescription

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

AP02_941_1311EN 1

No. 0 Designation
1 Emergency operation − transfer tube
2 Drive cylinder emergency operation

Special features of the pump control system

Emergency operation In the event of a control system failure, you can switch the transfer
of transfer tube/drive tube and operate the delivery cylinders alternately using emergency
cylinder operation. This will allow both forward pumping and reverse pump

ing.

376 AP02_941_1311EN
 Generaltechnicaldescription

3.7.3 Pressure gauge The hydraulic pressure of the hydraulic pump is shown on the
pressure gauge.

AP02_063_0308EN 1

3.7.4 Filter condition 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.

Suction filter

AP02_063_0308EN 2

Vacuum meter

Pressure filter

AP02_063_0308EN 3

Filter housing with indicator

AP02_063_0308EN 377
 Generaltechnicaldescription

3.8 Other components The other components of this machine are described on the follow

ing pages. The summary at the start of this chapter will show you
where the various components are located on the machine. The
symbols used on the other components are described in one of the
preceding sections.

The following components may be described here, depending on

the equipment on your machine.
− manual throttle lever for the engine
− flushing water pump
− high−pressure water pump
− compressor
− vibrator
− hydraulic fluid radiator

Note
Further control devices and components are described in the
Hy
draulic control devices" (from page 374) and
Electrical control
devices" (from page 320) sections.

378 AP02_059_9801EN
 Generaltechnicaldescription

3.8.1 Hydraulic fluid Some of the hydraulic fluid in the machine first flows through a radi

radiator ator before it returns to the reservoir. The hydraulic fluid radiator fan
is hydraulically powered, and runs once the machine is switched on.
The hydraulic fluid radiator cools the diesel engine and the hydraulic
fluid circuit of the concrete pump.

AP02_934_1310EN 1

No. 0 Designation
1 Hydraulic fluid return circuit
2 Hydraulic motor with fan
3 Hydraulic fluid supply circuit

AP02_934_1310EN 379
 Generaltechnicaldescription

3.8.2 Vibrator The vibrator is bolted to the grille. It causes the grille to vibrate and
thus prevents bridges forming on the grille, particularly in the case of
very stiff concrete. The vibrator is electrically driven; the connecting
plug must be plugged into the appropriate socket on the control
cabinet for this to work.

1
3

4
31201000

No 0 Designation
1 Grille
2 Vibrator
3 Supply cable
4 Plug

The vibrator is switched on and off from the control cabinet, or

optionally through the remote control.

380 AP02_014_9612EN
 4 Starting up

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

Information is available on how to check your machine and how to

carry out a test run with visual and function checks.

Note
The operating personnel must be instructed in the use of the
machine the first time it is started up.

AP13_015_0303EN
 Startingup

4.1 Visual checks You must check the condition of the machine and carry out a test run
with function checks each time before you start to use it. If you notice
a defect, you must have this rectified immediately, if necessary by
qualified personnel.

Note
Every time you use the machine, you accept full responsibility for the
safety of anyone located in the machine’s danger zone. You are
therefore under an obligation to ensure that the machine is com
pletely safe in operation.

4.1.1 Hydraulic system The fundamental prerequisite for problem−free use is a fully func

tional hydraulic system.

" Check that all hydraulic lines, threaded unions and cylinders
are tight.
Maintenance card: Hoses

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

AP13_022_0303EN 41
 Startingup

4.1.2 Functional fluids Making ready for operation also includes topping up the functional
fluids.

MAX

MIN

MAX

MIN

10000702

Water, fluid and fuel levels

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

Note
The machine must be level when you check the functional fluids. The
water box must be full during operation, even if there is a risk of
freezing.

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

42 AP13_022_0303EN
 Startingup

4.1.3 Condensate water Water of condensation can form in the hydraulic fluid reservoir and
settle 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 the
escaping condensate water.

" Open the drain cock. Close the cock again as soon as fluid
runs out.

4.1.4 Lubrication points

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

" Check that all lubrication points have been lubricated.

4.1.5 Hydraulic fluid

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

AP13_022_0303EN 43
 Startingup

4.1.6 Water box The water box is fitted between the drive cylinders and delivery
cylinders. 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 the
perforated plate.

Danger of crushing
You could suffer severe injuries from crushing or the shearing action
of components.

Never reach into the open water box to check it.

" Open the water box.

" Check the water level.

å The piston rods must be completely covered.

" Check the water condition.

å The drive cylinders are leaking if there is a clearly visible
escape of fluid, particularly at the piston rods.
å At least one of the delivery pistons is worn if the amount of
sludge in the water box is unusually high.

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

Maintenance card: Delivery piston replacement

" Close the water box again.

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

44 AP13_022_0303EN
 Startingup

4.1.7 Parts in contact You should always check the parts which come into contact with
with concrete concrete before using the machine:

" Disconnect the delivery line bend at the pressure connection.

" Illuminate the transfer tube from the pressure connection using
a pocket torch and check the inner wall of the pipe and its
thrust 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 replaced
if there is clearly detectable wear (e.g. deep grooves).

10701400

Check spectacle wear plate

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

Caution
The agitator grille must be closed and secured.

AP13_022_0303EN 45
 Startingup

4.2 Test run Depending on the machine’s equipment, the following sequence of
actions must be carried out for the test run:
− Opening the ventilation flap
− Open side flaps
− Switching on the machine

You must now check several functions with the machine running.

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

All operating and control elements on the control cabinet, in particu

lar the main switch and the EMERGENCY STOP button, must be
quickly accessible at all times during operation.

The side flap in front of the control cabinet must not be closed once
the engine has been switched on if the operating and control
elements would be covered.

46 AP13_023_0904EN
 Startingup

4.2.1 Switching on Before switching on the machine, you must set up the machine cor

the machine rectly, have the control cabinet connected to the electrical power
supply 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".

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

" Switch the agitator off.

" Turn the Increase − Reduce output" potentiometer on the

cable remote control to min".

2 AP13_109_1511EN 1

No. 0 Designation
1 SPC Display:
Displaying and Setting operating states
2 Ignition
starter switch: Diesel engine On−Off

AP13_109_1511EN 4—7
 Startingup

Note
To operate the machine locally, the
Local control" replacement con
nector must remain plugged into the
Local control − remote control"
socket on the control cabinet.

AP13_109_1511EN 2

No. 0 Designation
1 Local control" replacement connector

" Plug in the Local control" replacement connector.

" Switch on the diesel engine using the ignition
starter switch.

å The SPC Display lights up.

" Actuate the Deactivate EMERGENCY STOP" toggle switch

onthe control cabinet.

" Switch on the pump using the Forward pumping − 0 − reverse

pumping" toggle switch on the control cabinet.

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

" You can use the operating elements of the SPC Device to navi

gate in the menu structure and to make settings.

48 AP13_109_1511EN
 Startingup

4.3 Function checks Before using the machine on site, systematically check the functions
of the components with the machine running.

4.3.1 Pump The fundamental prerequisite for problem−free use is a fully

functional pump.

Switch over Check for an unimpeded switchover function of the delivery pistons
and the transfer tube at various engine speeds and positions of the
output controller.

Magnetic switches

AP13_026_0510EN 1

Checking the magnetic switches

Check that the drive cylinders switch over automatically once the
hydraulic pistons are close to the magnetic switches. The green
in−service lamp on the distributor casing must remain lit during
thisprocess. The yellow LEDs will light up briefly as soon as the
hydraulic piston approaches its magnetic switch. If one of the LEDs
does not light up, the associated magnetic switch is defective.

AP13_026_0510EN 49
 Startingup

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

Stroke time Measure the machine stroke time under no load, i.e. without
concrete.

" Set the engine to maximum speed.

" Set the maximum pumping rate.

" Start the measurement at the first switch over of the transfer
tube.
å The first single stroke is complete with the next transfer
tube 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 test
reading.

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

410 AP13_026_0510EN
 Startingup

4.3.2 EMERGENCY STOP It is only possible to intervene rapidly in the event of danger if all
buttons EMERGENCY STOP buttons on the machine and on the remote
control are functioning correctly.

Caution
The machine is no longer safe to operate if an EMERGENCY STOP
button is defective, as you will no longer be able to switch off the
machine quickly enough if danger threatens. You must therefore
check the functioning of the EMERGENCY STOP buttons each time
you start work.

EMERGENCY STOP
button

10500200

Press: lock EMERGENCY STOP

Turn: unlock EMERGENCY STOP

" Switch the pump on.

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

" Press one of the EMERGENCY STOP buttons.

å The pump must stop immediately.

" Check all EMERGENCY STOP buttons on the machine and

onthe remote control in the same way.

AP13_027_0904EN 411
 Startingup

4.3.3 Function check of the This machine is equipped with an agitator safety cutout. As soon as
agitator safety cutout you open the grille, the signal between the transponder and reading
(RSA) head is broken. This causes the agitator to halt and the pressure to
be dumped from the accumulator, i.e. the transfer tube will no longer
be able to switch over. In addition, the delivery pistons return to the
end position and the concrete pump halts.

Danger
Risk of injury when the agitator is operating and the transfer tube is
switching.

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

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

Before acknowledging the agitator safety cutout, check that noone

is 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.

412 AP13_075_1202EN
 Startingup

1 2 3

AP13_075_1202EN 1

No. 0 Designation
1 Transponder (in the grille)
2 LED, green and red
3 Acknowledge agitator or agitator safety cutout
on the EPS/EGD control cabinet
4 Reading head (on the hopper − example illustration)

" Open the grille with the concrete pump running.

å The transponder signal is broken.
å The agitator must come to a halt immediately.
å The transfer tube must no longer switch over.
å The concrete pump must run to the end position and halt.

Note
To restart, you must first acknowledge the agitator or agitator safety
cutout toggle switch on the control cabinet.

AP13_075_1202EN 4 — 13
 Startingup

4.3.4 Acknowledge the agi- The agitator is secured against unexpected restarts. When the ma

tator safety cutout chine is started up after the agitator safety cutout has been actuated,
the agitator safety cutout must be acknowledged before the concrete
pump can be switched back on.

The agitator safety cutout is triggered in the following situations:

− when the grille is opened
− when the PTO is switched off
− when the ignition is switched off

Danger
Risk of injury when the agitator is operating and the transfer tube is
switching.

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

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

Before acknowledging the agitator safety cutout, check that noone

is 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.

414 AP13_076_1202EN
 Startingup

AP13_076_1202EN 1

No. 0 Designation
1 Acknowledge agitator or agitator safety cutout
on the EPS/EGD control cabinet

" Actuate the Acknowledge agitator or agitator safety cutout"

toggle switch on the EPS/EGD control cabinet.

AP13_076_1202EN 4 — 15
 Startingup

4.3.5 Filter condition Dirty filters reduce the fluid flow considerably so that damage may
occur in the hydraulic system.

" Bring the hydraulic fluid up to operating temperature (u50_C).

" Set the maximum pumping rate.

Note
The indicators on the filters can only be checked under load once
the hydraulic fluid has warmed up.

Please read the
Filter change" maintenance card.

Suction filter

10300200

Vacuum meter

Note
You must replace the filter element if the pointer on the vacuum
meter is in the red zone at more than 50_C fluid temperature and
atthe shortest stroke time.

416 AP13_029_0308EN
 Startingup

Pressure filter

AP13_029_0308EN 1

Pressing down the red button

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

Note
You must replace the filter element if the red button pops out again
after a short time.
The filter is OK if the red button remains depressed.

Environmental protection
Comply with the waste disposal regulations in force for your area
when changing the fluid filter.

AP13_029_0308EN 417
 Startingup

4.3.6 Agitator The agitator hopper grille must always be closed when the pump is
in operation.

1a

1b

1 AP13_110_1511EN 1

No. 0 Designation
Agitator On − agitation direction away from the delivery
cylinder(1a)
1 Agitator Off
Agitator On − agitation direction towards the delivery
cylinder(1b)

" Actuate the toggle switch on the control cabinet and check the
two directions of rotation, one after the other.

418 AP13_110_1511EN
 Startingup

4.3.7 Vibrator The vibrator is electrically driven so an electrical connection must

first be made between it and the control cabinet.

1
3

4
31201000

" Check that the vibrator is functioning correctly.

Note
The vibrator will only function when the switch for the pump is on at
the control cabinet and at the remote control.

AP13_034_0303EN 419
 Startingup

4.3.8 Switching off You can shut down the machine after completing the function
the machine checks. When you shut down the machine, you must perform the
following tasks:

" Switch off the pump at the control cabinet.

" Switch off all power consumers.

" Switch off the engine at the control cabinet.

" Switch the main switch off.

å The Ready for Service" indicator lamps go out.

Caution
Do not switch off the engine when running at full load.

Only use the EMERGENCY STOP button in the event of danger.

420 AP13_021_0904EN
 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 are
also described.

AP06_001_1007EN
 Transport,settingupandconnection

5.1 Transport Various methods of transporting your machine are possible. Loading
the machine onto a transport vehicle is always one method. The
other methods depend on how your machine is equipped.
− Machines with an F80 chassis can travel on public highways.
− The machine can be moved in the same way as a trailer if fitted
with an F8 chassis, but movement is restricted to the construction
site. The maximum speed at which it may be moved is 8km/h. The
machine is not authorized for use on the public highway so you will
have 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.

5.1.1 Loading Lifting eyes will need to be fitted to the machine should you wish to
load it onto a transport vehicle. Any lifting eyes fitted to your machine
for the purpose of lifting it will be located on the top of the machine
and may be identified by their colour.

Suspended load
Raised loads may fall if they are not loaded properly or if the slings
and eyes are damaged.
You should, therefore, never walk under suspended loads.

Caution
The machine may only be loaded by crane if it is equipped with suit
able lifting eyes. Lifting equipment, lifting tackle, support trestles and
other auxiliary equipment must be reliable and safe in operation.
Make sure that the loadbearing capacity is adequate. Always lift the
machine by all its lifting eyes, otherwise too great a load could be
placed on individual lifting eyes.

The machine must be properly secured on the transport vehicle to

prevent it rolling away, slipping or tipping over.

AP06_003_1007EN 51
 Transport,settingupandconnection

5.1.2 Lifting eyes Use the lifting eyes as shown.

Note
The lifting eyes fitted to your machine for the purpose of lifting are
located 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 so

that it cannot roll away.

AP06_003_1007EN 1

Suspend by all lifting eyes

1 Rope angle > 45_

" Hook a four−cable sling to the 4 lifting eyes.

Danger
The 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 hoist
the machine vertically.

" Hoist the machine vertically.

" Place the machine on a suitable transport vehicle and lash it

down securely.

52 AP06_003_1007EN
 Transport,settingupandconnection

Suspended load
Use only appropriate lifting gear. Suspend the BSA from the lifting
eyes specified.
Never hoist the load over people. Take note of the safety regulations
for crane operations.

BSA

AP06_003_1007EN 2

4 lifting eyes

AP06_003_1007EN 53
 Transport,settingupandconnection

5.1.3 Chassis Your machine may be mounted on different chassis models or on a

static base structure, depending on the specification. The chassis
model is stated on the machine card and the maximum permitted
speed is stated on the rating plate.

5.1.4 F 8 chassis The machine may not travel on public roads if fitted with an F8 chas

sis. Towing the machine as a trailer is restricted to the construction
site or private property.

Caution
The machine must not exceed a maximum speed of 8km/h when
under tow if fitted with an F8 chassis.

You must load the machine onto a suitable transport vehicle to trans

port it to the construction site (see Loading").

5.1.5 F 25 chassis The machine may not travel on public roads if fitted with an F25
chassis. Towing the machine as a trailer is restricted to the construc

tion site or private property.

Caution
The machine must not exceed a maximum speed of 25km/h when
under tow if fitted with an F25 chassis.

54 AP06_039_1211EN
 Transport,settingupandconnection

5.1.6 F 80 chassis The machine may travel on public roads in the same way as a stan

dard trailer if fitted with an F80 chassis.

Note
Stationary concrete pumps can only be driven on public roads if they
have the appropriate approval. The driver of the tractor unit must
have the relevant driving licence.

If you have to drive in reverse you must always ask for a signaller to
guide you. If necessary, have the route cordoned off or secured by
assistants. Have the site management arrange for the removal of any
materials or equipment that hinder your approach.

Hand signals

10000331

For hand signals, see the chapter Hand signals for driving"

" Agree clear hand signals with the signaller before moving off.

AP06_039_1211EN 55
 Transport,settingupandconnection

Before moving off There are several tasks you will need to perform before joining the
public road, including the following:

Caution
If you have changed the tyres, you must retighten the wheel nuts
after approximately 50km.

See the spare parts sheet for the tightening torques.

" Check that the vehicle is safe to drive (lighting, brakes, tyre
inflation pressures, wheel nuts etc.).

" Clean the machine so that it does not soil the public roads.

" Check that the accessories are secure.

Danger
Supports extending spontaneously whilst the truck is moving can
cause serious accidents. Fit the transport security devices (such as
spring pins).

" Check to make sure that the support legs are secured for
driving.

" Observe the permissible gross laden weight.

" Check that the oil and water tanks are not leaking and that they
are securely closed.

56 AP06_039_1211EN
 Transport,settingupandconnection

During the journey The size and weight of the truck demand particular caution when
driving.

" Keep an adequate distance from slopes and pits.

" Only drive over arches, bridges or other supporting structures

if the load
bearing capacity is adequate.

" Be aware of the elevated position of the truck’s centre of gravity

when travelling on a slope and on ascending or descending
routes.

You must load the machine onto a suitable transport vehicle to trans

port it to the construction site (see Loading").

5.1.7 Crawler track Your machine can be towed by a tractor unit if fitted with a crawler
track.

Note
Observe the manufacturer’s operating and maintenance instructions.

The machine is neither equipped nor approved for travel on public

roads.

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

AP06_039_1211EN 57
 Transport,settingupandconnection

5.2 Hand signals for It is often necessary to have a signaller help by directing you when
driving you are driving to the set−up site on construction sites where space
is restricted. Clear hand signals must be agreed between signaller
and machine operator. Below you will find some suggestions for
hand signals to be used when driving.

Stop Extend both arms out to the

side.

10000306

Drive to the left With the arm crooked, point

with the thumb in the direction
the truck should steer.

10000301

Drive to the right With the arm crooked, point

with the thumb in the direction
the truck should steer.

10000302

58 AP06_031_1007EN
 Transport,settingupandconnection

Drive towards the With the arm crooked, wave the

signaller palm in the direction the truck
should drive.

10000303

Drive away from the With the arm crooked, wave the
signaller palm in the direction the truck
should drive.

10000304

Clearance With the arm crooked, indicate

the distance to an obstacle with
the palms of the hands.

10000305

AP06_031_1007EN 59
 Transport,settingupandconnection

5.3 Requirements for the As a rule, the site management determines the set−up site for the
set–up site machine and prepares the site accordingly.

Note
The machine operator takes responsibility for setting up the machine
safely.

" Inspect the proposed site carefully and reject the set−up site if
you have any doubts in respect of safety.

On stationary concrete pumps that are equipped with a system for

exhaust gas treatment, regeneration procedures (stationary regener

ation) are regularly triggered automatically or, if required, activated
manually.

Danger of fire
Danger of fire due to inadequate clearance from a stationary con
crete pump during the regeneration procedure.
During the regeneration procedure in particular, very high exhaust
gas and surface temperatures occur near a stationary concrete
pump (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.

510 AP06_005_1508EN
 Transport,settingupandconnection

Danger of poisoning
Injuries to the respiratory passage.
Vehicle exhaust gases contain constituents that can be deadly or
carcinogenic.
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.

Accessibility 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 all
sides. You must be able to open all the guards, flaps and hoods
without obstruction.

" Ensure that there is sufficient clearance around the entire ma

chine.

Approach route The approach route must be sufficiently firm that so it can be driven
over regardless of the weather conditions. Walk along the approach
route before you drive over it. Ask for a signaller if you need to re

verse.

Space for truck The approach route to the concrete pump must be firm enough that
mixers it can be driven over by truck mixers regardless of the weather
conditions.

There must be sufficient space around the concrete pump for truck
mixers to manoeuvre and turn.

There must be sufficient space around the hopper for two truck
mixers to unload at the same time.

AP06_005_1508EN 511
 Transport,settingupandconnection

Supporting ground The supporting ground must be firm enough to absorb the forces
conducted by the support feet into the ground. There must not be
any 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 blocks
or 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 for
a prolonged period.

It is recommend that concrete pumps working at high−pressure and

high delivery rate are securely anchored.

512 AP06_005_1508EN
 Transport,settingupandconnection

Minimum clearance A minimum distance must be maintained from pits, slopes, excava

from pits tions etc. so that the machine cannot topple over.

45°
12100401

Minimum clearance a

The minimum clearance a" for machines with a gross weight of up

to 12 tons is 1 metre

" Maintain a distance from pits, slopes, trenches etc., when ap

proaching the set−up site.

Lighting The set−up site must be adequately illuminated in order to ensure

safe working on the machine.

" Ensure that the set
up site is adequately lit.

Draining away wash- Draining of the washing water must be ensured (e.g. using a sew

ing water age pump), and particularly if the concrete pump has been set up in
a pit or trench.

AP06_005_1508EN 513
 Transport,settingupandconnection

5.4 Setting up The machine must be level. Pay attention to the section headed
Requirements for the set
up site".

" Drive the machine to the inspected set
up site.

1 2 2

AP06_070_1403EN 1

Initial situation

Pos.0 Designation
1 Support wheel
2 Support leg with support foot

" Use chocks to secure the machine against rolling.

" Wind the support wheel down and disconnect the machine
from the tractor unit.

514 AP06_070_1403EN
 Transport,settingupandconnection

AP06_070_1403EN 2

Lowering the drawbar at the front

" Wind up the support wheel in order to lower the drawbar.

AP06_070_1403EN 515
 Transport,settingupandconnection

AP06_070_1403EN 3

Supporting the rear

" Place timber blocks or other suitable material beneath the rear
support feet.

" Unlock the rear support feet by removing the spring pins from
the locking bolts and then removing the bolts.

" Extend the rear support feet until the machine is level once it is
supported.

" Reinsert the locking bolts in the last possible hole and secure
them with the spring pins.

516 AP06_070_1403EN
 Transport,settingupandconnection

AP06_070_1403EN 4

Raising the machine and supporting at the front

" Use the support wheel to raise the machine until the forward
support feet can be extended to exactly the same extent as the
rear feet.

" Place timber blocks or other suitable material beneath the for

ward support feet.

" Unlock the forward support feet by removing the spring pins
from the locking bolts and then removing the bolts.

" Extend the forward support feet to the same extent as the rear
support feet and reinsert the locking bolts.

" Secure the locking bolts with the spring pins.

AP06_070_1403EN 517
 Transport,settingupandconnection

AP06_070_1403EN 5

Machine set up correctly

" Wind up the support wheel.

å The wheels are no longer in contact with the ground when
the machine is supported.

Note
Sudden pulsations from the delivery line may be transmitted to the
machine under extreme operating conditions (e.g. highpressure
delivery). These pulsations could jeopardise the stability of the
machine.

The support feet can be anchored to the ground (e.g. concreting

them in or lashing them down with tensioning chains) to give the
machine greater stability.

518 AP06_070_1403EN
 Transport,settingupandconnection

5.5 Stationary When pumping concrete, you must only use perfect and safe deliv

delivery line ery lines, couplings and seals. The delivery lines and couplings must
be specially designed for the pressure specified on the pump rating
plate. The delivery lines are subject to wear, which is dependent
upon:
− the concrete pressure
− the concrete composition
− the delivery line material.

10
9
8
7
6

5
4
3
2
1

AP06_014_1007EN 1

No. 1 Designation
1 Pressure pipe
2 Bolted coupling
3 Reducer
4 Clamp coupling
5 Pipe bracket
6 Delivery pipe (adapter pipe)
7 Clamp coupling
8 Pipe bracket
9 Vibration damper
10 Delivery pipe (adapter pipe)

AP06_014_1007EN 519
 Transport,settingupandconnection

5.5.1 Danger zone

3m
AP06_014_1007EN 2

Danger zone for stationary delivery lines

Danger
Serious 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

520 AP06_014_1007EN
 Transport,settingupandconnection

5.5.2 Instructions for laying The stationary delivery line can be laid horizontally over the ground,
the line or vertically or inclined against walls. The entire length of the delivery
line 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 fitted
and removed. Double wooden chocks (see illustration) are
most suitable as they allow for longitudinal and latitudinal
movement 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 difficult
to access.

" Begin laying the delivery line at the concrete pump as other

wise you will have to line up the concrete pump to the delivery
line.

AP06_014_1007EN 521
 Transport,settingupandconnection

AP06_014_1007EN 5

Delivery line leading away at a right angle to the concrete

pump

" Route the stationary delivery line away from the concrete pump
at right angles to it. This minimizes the effect of pump pulsa

tions which may be transmitted from the delivery line to the
pump and vice versa.

" Guide the delivery line in the direction of the arrow away from
the concrete pump. The operator’s side of the concrete pump
is then not in the danger zone.

" Fit only as−new delivery pipes near the pump, as the concrete
pressure 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, transfer
tubes, gate valves etc.

522 AP06_014_1007EN
 Transport,settingupandconnection

5.5.3 Fastening Pump pulsations occur when pumping concrete. These are caused
by the pump itself and are transmitted to the delivery line system.
The stationary delivery line must be safely secured and stabilised on
the supporting ground.

Danger
There 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 or
scaffolding, check whether the scaffolding can bear the load.

Horizontal All horizontal delivery lines must be anchored on the supporting

delivery line ground.

" Use pipe brackets which are secured to a suitable supporting

ground capable of bearing the load
å The pump pulsations are reduced and the delivery line is
prevented from bending.

AP06_014_1007EN 6

Fastening the delivery line

AP06_014_1007EN 523
 Transport,settingupandconnection

Fixed point A fixed point is a 1−2m3 large, reinforced lump of concrete with a
delivery 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.

å The pump pulsations are reduced and the delivery line is
prevented from bending.

AP06_014_1007EN 7

Elasticity of the delivery line using a fixed point

524 AP06_014_1007EN
 Transport,settingupandconnection

Vertical (angled) Vertical or angled delivery lines leading upwards or downwards must
delivery line always be fastened to the structure or background so that they are
self−supporting. The delivery line must not be supported by the
lowest pipe bend.

AP06_014_1007EN 8

Fastening the delivery line

The lowest elbow should be a thick−walled 90° cast elbow with a

radius of 1m.

AP06_014_1007EN 525
 Transport,settingupandconnection

Risers The delivery line is called a riser where it is laid in such a way that
the concrete is pumped upwards.

Gate valve The weight of the concrete in the riser exerts a force on the concrete
pump (approximately 30kg per metre of continuous pipe) when the
pump is switched off.

" Install a gate valve at the start of the riser.

å The delivery line can be closed off so that the pressure
bears on the gate valve and not on the concrete pump.

Downpipes The delivery line is called a downpipe if it is laid in such a way that
the concrete is pumped downwards.

Gate valve The concrete flows down through the delivery line under its own
weight 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.

å The delivery line can be closed off so that the concrete
cannot flow out of the delivery line.

526 AP06_014_1007EN
 Transport,settingupandconnection

5.5.4 SK delivery line When laying Putzmeister SK delivery pipes, maintain a gap of 4mm
system between the individual pipes.

Note
Grease all couplings and seals well internally before assembly. Use
a lithium soap base multipurpose grease with the marking K2K.

4mm

AP06_014_1007EN 9

Putzmeister SK delivery line with clamp coupling, A seal and

spring pin

" Secure each clamp coupling with a spring pin.

AP06_014_1007EN 527
 6 Pumping operations

This chapter contains information regarding the operation of the

machine for pumping. You will learn what steps are required for
pumping and cleaning.

AP07_026_9710EN
 Pumpingoperations

6.1 Preconditions You must have carefully completed the operations required to start
up and set up the machine before you start pumping.

Before you fill the hopper with concrete and pump it through the
delivery 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.

Note
If a malfunction occurs during the pumping operation, you must stop
your 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 lengthy

downtimes and high repair costs.

AP07_069_1007EN 61
 Operation

6.1.1 Remote control 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.

Caution
Carry the remote control in such a way that no control elements
canbe actuated unintentionally. Do not damage the remote control
cable. Malfunctions may otherwise occur.
Never put the remote control down when the machine is ready for
operation. If this is unavoidable in exceptional cases, you must
switch off the remote control, disconnect it and lock it away.

Danger
Risk to life from unintended machine movements. The range of
aradio remote control is great enough for the machine to receive
control commands (e.g. from a great distance, from inside enclosed
spaces), even without visual contact. In such cases, signallers MUST
be used, and must remain in contact with the machine operator
using suitable means, and have visual contact with the site of
concrete placement, work and danger zones and the machine.

62 BP07_051_1109EN
 Pumpingoperations

6.2 Hand signals for It is particularly important that the machine operator at the concrete
pumping pump and the concreting gang working at the placement site can
communicate with each other if accidents are to be avoided when
pumping. Communication is particulary important in long−distance
and high−rise pumping where the machine operator cannot see the
site of concrete placement. Communication may be via unambiguous
and 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 this
chapter. They are based on DIN24081, DIN33409 and guideline
RI/08.90/2 issued by the German Construction Employers’ Liability
Insurance Association, amongst other guidelines. The direction of
movement is specified from the machine operator’s direction of view.

EMERGENCY STOP Extend both arms outwards

and move up and down
quickly.

10000308

Slow Place a fist on the helmet.

10000307

AP07_029_0905EN 63
 Pumpingoperations

Increase output/ The thumb of one hand points

Start pumping upwards. The palm of the
other hand is held over it.

10000327

Reduce output The thumb of one hand points

downwards. The palm of the
other hand is held under it.

10000328

Reverse pumping The crooked elbow of one arm

points downwards into the
palm of the other hand.

10000329

Stop pumping Grip both hands together over

the head.

10000330

64 AP07_029_0905EN
 Pumpingoperations

6.3 Filling the machine Your machine is driven by a diesel engine. The fuel tank is built into
with fuel the superstructure, its filler pipe is on the top. You may refuel the
machine, once it is switched off, through the filler pipe.

Note
Refill the fuel tank in good time, as otherwise you will have to bleed
the fuel line to the diesel engine.
Fill the fuel tank with commercially available branded diesel fuel only,
as otherwise the diesel engine can be damaged.
Use summer or winter−grade diesel fuel according to the outside
temperature.

Caution
Only fill the machine with fuel with the engine switched off.

Pay attention to accuracy when filling the machine with fuel.

Do not spill a single drop of fuel.

AP07_023_0303EN 65
 Pumpingoperations

6.4 Considering concrete Properties of the concrete such as its consistence and grading curve
properties are decisive factors for the optimum fill level of the delivery cylinders.
The fill level influences the level of efficiency of the pump, i.e. the
output per stroke.

Saturated mix

2
1

11000401

No. 0 Description
1 Aggregate
2 Cement paste
3 Boundary layer

Note
A 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, reducing
the speed of pumping can increase the output.

66 AP07_031_0304EN
 Pumpingoperations

6.5 Filling the agitator

hopper

AP07_027_0303EN 1

Always fill the agitator hopper with concrete

up to the mixer shaft.

Danger
Entrapped air in the delivery line is dangerous as the compressed air
is released suddenly at the end of the delivery line and the concrete
can be blown out explosively. No air must be sucked in for this
reason.

You should therefore always fill the agitator hopper with concrete up
to the mixer shaft during pumping operations.

AP07_027_0303EN 2

Danger from escaping compressed air

AP07_027_0303EN 67
 Pumpingoperations

6.6 Starting pumping The process from the start of forwards pumping to the time at which
a continuously flowing concrete stream exits from the delivery line is
known as starting to pump. This may be at the start of the site use, or
also 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 the
wash−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 two

sponge balls and a solid concrete stream exit from the delivery line.

Note
You must begin pumping with a cement−water mixture (grout) if the
delivery lines are new, or if the delivery line has not been used for a
long time.

68 AP07_032_9710EN
 Pumpingoperations

6.7 Pumping Correct mixing of the concrete influences pumping performance.

" Mix the concrete vigourously in the truck mixer at maximum

speed. Ensure that the concrete mix is uniformly prepared.

" Concrete additives (deflocculants, set retarding admixtures)

must be mixed in for at least 4minutes after they are added.

" Pour the concrete from the truck mixer, silo, etc into the agitator
hopper.

" Switch the agitator on.

" Begin delivery.

Note
Start with a low output and increase this continuously after several
cubic metres.

A machine driven by a diesel engine can be run more economically

by selecting engine speed and output regulation such that the
engine does not rev too highly when under low load.

AP07_034_9710EN 69
 Pumpingoperations

6.7.1 Monitoring The displays of the monitoring instruments must be kept under
observation during pumping operations.

1 2

3
10301100

No 0 Designation
1 Vacuum meter
2 Hydraulic fluid temperature gauge
3 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 is
contaminated or the hydraulic fluid is too cold.
− Fluid temperature gauge: the fluid temperature must not exceed
90_C.
− Hydraulic pressure gauge: the value indicated must not exceed
the maximum value specified on the machine card.

610 AP07_035_9710EN
 Pumpingoperations

Note
You must repeat these checks at regular short intervals all the time
the machine is running.

Danger
The machine must be switched off every time a fault is indicated. All
faults must be rectified immediately, otherwise the guarantee will be
invalidated.

" 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.

Note
The bearings and seals must be replaced as soon as a cement−
coloured fluid and grease mixture or slurry begins to escape.

AP07_035_9710EN 611
 Pumpingoperations

6.7.2 Blockages
2
1

3
11000601

No 0 Designation
1 Wedged aggregate
2 Cement paste
3 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

Caution
In the event of blockages, pump the concrete immediately back into
the agitator hopper and mix it up. You can switch over to forwards
pumping when the delivery cylinders and the transfer tube are
switching over automatically again without problem. Begin pumping
again with care.

612 AP07_037_9710EN
 Pumpingoperations

6.7.3 Breaks in pumping 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 segregated
due the the vibrations of the machine. Note the following points if
breaks 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 intervals
by forward and reverse pumping.
− You should avoid breaks when pumping concrete with a low water
retentivity (tendency to bleeding) as the vibrations can segregate
the concrete. You must always leave the pump switched to reverse
pumping when you begin pumping again and wait for the transfer
tube to switch across fully on both sides. Only then can you switch
over to forwards pumping again.
− Pump the concrete back into the agitator hopper before long
breaks in pumping. You must mix the concrete again before you
recommence pumping.

Note
Reverse pumping is only possible for a few pump strokes, otherwise
the hopper overflows.

Caution
Never use force to pump segregated concrete or concrete that has
become lumpy because it is beginning to set into the delivery line.
Blockages can very easily be caused in this way.

AP07_038_9710EN 613
 Pumpingoperations

6.7.4 Engine Do not exceed the permissible engine speed specified in the ma

chine card and on the machine rating plate. Always set the engine
speed higher than the vibrating speed. Do not shut down the engine
immediately after periods of heavy engine loading, but first allow it to
cool down at idling speed.

6.7.5 Overheating During normal pump operation, the temperature of the hydraulic fluid
is between 70_C and 80_C.
The following may cause the hydraulic fluid to overheat, particularly
ifseveral 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 keeps
running to provide cooling and a red indicator lamp lights up on the
control cabinet. Proceed as follows to prevent a shut−down in the
middle 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.

614 AP07_056_0304EN
 Pumpingoperations

Cooling

10600200

" Change the water frequently if the temperature continues

torise.

" Trace the cause of fluid overheating and rectify it.

Additional cooling If necessary, you can cool the drive cylinders with a water jet if the
measures described above are not adequate.

10600400

" Direct the water jet at the drive cylinders and piston rods for
the drive cylinders.

Caution
Never use sea water or salt water for cooling. Otherwise the chrome
layer on the delivery piston rods and delivery cylinders will be
destroyed.

AP07_056_0304EN 615
 Pumpingoperations

6.7.6 Restarting Proceed as follows if the pump has nevertheless switched off
because of overheating:

" Set the output controller to min".

Note
Never switch the engine/motor off, as the radiator must remain in
operation.

" Refresh the water in the water box.

" Wait until the fluid has cooled if you are not able to find the fault
immediately.

" Once the red indicator lamp has extinguished, switch the
pump back on and continue pumping slowly at reduced
output.

" Determine the cause of the fluid overheating once pumping

operations have been completed and rectify the fault.

616 AP07_058_0303EN
 Pumpingoperations

6.8 Emergency operation The hydraulic control valves are built into the pump control system.
– pump function They are only for emergency manual operation of the machine when
the control system fails.

Note
For 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.

Example of OPS
pump control system

AP07_076_1311EN 1

Item 0 Designation
1 Emergency operation − transfer tube
2 Drive cylinder emergency operation

AP07_076_1311EN 617
 Pumpingoperations

Operating the OPS pump control system

Drive cylinder In order to be able to move the piston to the cylinder end position,
emergency operation operate the drive cylinderemergency operation(2).

Emergency operation − In order to be able to switch over the transfer tube, keep the drive
transfer tube cylinder emergency operation(2) pressed, while at the same time
operating the transfer tube emergency operation(1).

Note
Press and hold the drive cylinder emergency operation and the
transfer tube emergency operation until the transfer tube switches
over.

618 AP07_076_1311EN
 Pumpingoperations

6.9 Cleaning Concrete leavings that are deposited inside the delivery line or
transfer tube can cause damage, will accumulate and reduce the
cross section. A clean delivery line and transfer tube is therefore in

dispensable if you wish to be able to start pumping without problems
on the next job.

Concrete leavings deposited around the wear ring can impair its
function. For this reason, thorough flushing of the wear ring is re

quired at the end of a job, unless the next pumping job follows within
30−60minutes.

Cleaning instructions

Caution
To ensure that you do not damage the paint and other surfaces of
your 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 on
the 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 40−50cm from the paint
surface.

You must also observe the following during the first 8weeks 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. The
remote control unit does not have a watertight casing. Perform the
machine functions required during cleaning operations from the con
trol cabinet.

AP07_040_1009EN 619
 Pumpingoperations

Concrete leavings You should always find an appropriate use for the concrete leavings
to help in environmental protection.

Environmental protection
The concrete leavings should be used on the construction site. If this
is not possible, the concrete leavings should be used as building
rubble or be recycled.

We recommend that you use the Putzmeister
Leavings sheet" to

allow you to make use of the concrete leavings. You can lay this
down under the hopper before opening the hopper flap. The con
crete then flows out into the sheet and can be transported to the site
of 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 a
site crane.

620 AP07_040_1009EN
 Pumpingoperations

Danger
Leave the agitator grille closed during all cleaning operations, since
you 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 the

hopper cannot be secured. There is a risk of injury by crushing or
loss of limb by shearing if you reach inside. It is prohibited to reach
through the hopper flap into the hopper from below.

AP07_040_1009EN 1

Do not reach into the hopper.

Compressed air cleaning

Danger
There is an increased risk of accident when cleaning with com
pressed air. The cleaning operation must only be carried out by a
specialist or under expert supervision. Putzmeister accepts no liabil
ity for damage caused by cleaning with compressed air, if performed
incorrectly. All persons participating in the cleaning procedure must
be instructed in the safety regulations.

AP07_040_1009EN 621
 Pumpingoperations

6.9.1 Preparations We recommend that you carry out the preparations described below
for cleaning in good time to allow you to clean the delivery line and the concrete
pump directly the site use is completed.

Sponge balls and

otheraccessories

2
4

10003401

1 Sponge pig
2 Sponge cube
3 Sponge ball
4 Wash−out pig

You will need sufficient numbers of sponge balls and other cleaning
accessories to clean the machine properly.

622 AP07_041_9712EN
 Pumpingoperations

Catch basket You must use the catch basket if you wish to force the concrete out
of the end of the pipe using water pressure or compressed air. It
must 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.

Danger
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, as
otherwise there is a risk of injury from the wash−out sponge and
concrete as they are expelled.

The use of the catch basket is recommended when water is used to

force out the concrete to ensure that the delivery line is sealed off
and no water can escape.

4
31201501

1 Coupling
2 Catch basket (closed pipe section)
3 Spring pin (on both sides)
4 Catch bracket

AP07_041_9712EN 623
 Pumpingoperations

Wash−out adaptors The wash−out adaptor is used when the machine is cleaned using
water under pressure or compressed air.

Danger
The wash−out adaptor must not be fitted to the delivery line while
pump is running as the wash−out connections and shut−off valves
are 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 10bar.

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, as
otherwise there is a risk of injury from the wash−out sponge and
concrete as they are expelled.

5 4 3
31201503

1 Pressure gauge
2 Guard bracket
3 Connection for water under pressure or compressed air
4 Shut−off valve for connection
5 Pressure dump bend
6 Dump cock

624 AP07_041_9712EN
 Pumpingoperations

T−delivery pipe with The T−delivery pipe with wash−out port can be used when cleaning
wash−out port with water under pressure. It allows the wash−out sponges to be
inserted quickly.
It traps the wash−out sponge in suction cleaning.

2
1

AP07_041_9712EN 1

1 T−delivery pipe with wash−out port

2 Wash−out port lid

Danger
Make sure that the T−delivery pipe is also designed for the pressure
stated on the pump rating plate.

You must only open the wash−out port lid once the pressure in the
delivery line has been dumped.

AP07_041_9712EN 625
 Pumpingoperations

Cement bags for Cement bags soaked in water and rolled up have proved useful
high−pressure when cleaning the delivery line using water under pressure. The
watercleaning cement 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 about

5minutes before starting the cleaning operation.

Note
You may also prepare a short pipe section containing the cement
bags and a wash−out sponge before you start the cleaning oper
ation.

10003502

626 AP07_041_9712EN
 Pumpingoperations

Mark the water hose The best way to clean the wear ring and seal ring on the transfer
tube is to rinse this area with water for some time from close up. You
must mark the water hose as described below to ensure that the
hose does not get cut by the switching transfer tube during cleaning.

Danger
The machine must be switched off and the hydraulic system, includ
ing the accumulator, fully depressurized when you are measuring the
hose length required, as otherwise there is a risk of injury as the
transfer tube switches over.

AP07_041_9712EN 2

1 Adhesive tape marking

" Measure the hose length required on the outside of the transfer
tube. The nozzle on the hose should be located shortly before
the seal ring so that concrete leavings are washed away from
the area around the wear ring and seal ring when the nozzle is
set to spray.

" Mark the measured length on the hose with adhesive tape, or
similar.

AP07_041_9712EN 627
 Pumpingoperations

6.9.2 Delivery line There are a number of options for cleaning a delivery line. Some of
the factors affecting which cleaning method you use include how the
concrete pump has been used and what equipment you have avail

able.

How to clean which Overleaf you will find a summary showing which cleaning method
delivery line isrecommended for the delivery lines listed. The symbols used in
the summary are explained below. The cleaning procedures are
described in the following sections.

The delivery line is connected to the concrete pump.

The leavings are pumped by the concrete pump out of
the hopper and onwards to the site of concrete place

ment. Cleaning is from the hopper onwards to the site
of concrete placement.

The delivery line is connected to the concrete pump.

The leavings are sucked back by the concrete pump
from 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 the
start of the delivery line to the site of concrete place

ment using an external force (compressed air or water
under 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 from
the site of concrete placement to the start of the delivery
line to using an external force (compressed air or water
under pressure). Cleaning is from backwards from the
site of concrete placement to the start of the delivery
line.

Recommended method of cleaning

Method of cleaning not recommended

Prohibited method of cleaning

Method of cleaning not possible

628 AP07_042_9712EN
 Pumpingoperations

Overview of the cleaning procedures for the stationary delivery line

Leavings
from

Delivery line to

Method of
cleaning

Compressed air

Horizontal line Water under pressure

Suction cleaning

Compressed air only with

special
Riser Water under pressure equipment

Suction cleaning

Compressed air only with

special
Downpipe Water under pressure equipment

Suction cleaning

AP07_042_9712EN 629
 Pumpingoperations

Suction cleaning Suction cleaning is the simplest and least hazardous method of
cleaning a riser. The method is described below.

" Pump the agitator hopper out until the concrete is at the level
of 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 of

the delivery line at the site of concrete placement.

" Switch the pump to reverse pumping.

å The concrete and the wash−out sponge are pumped back
through the delivery line.

Check for the

wash−outsponge

AP07_043_9712EN 1

Tapping on the delivery line with a hammer handle

" Tap on the delivery line with a piece of hardwood (hammer

handle) just ahead of the cleaning eye during the washing out
process.

630 AP07_043_9712EN
 Pumpingoperations

Note
Tapping produces deep dull noises there is concrete in the delivery
line. Tapping will yield high, clear sounds as soon as the concrete
and wash−out sponge have passed the point at which you are
tapping.

Use only a hammer handle to tap on the delivery line, as otherwise

the pipe may be damaged.

" Switch the pump off as soon as the wash−out sponge has
passed the point at which you are tapping.

Trapping the
wash−outsponge

AP07_043_9712EN 2

Turn the wash−out port lid round

" Open the wash−out port on the T−delivery pipe, turn the
wash−out port lid round and close it again with the pin pointing
inwards.

" Switch the pump back to reverse pumping.

å The wash−out sponge will be trapped on the pin of the
wash−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.

AP07_043_9712EN 631
 Pumpingoperations

High–pressure High−pressure water cleaning, which is more thorough, but more

water cleaning time−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 the
pressure on the delivery line by 1 or 2 strokes of reverse
pumping.

" Switch the pump off.

Introducing the
wash−out sponge

1 2

AP07_045_9712EN 1

1 Prepared pipe section for cleaning

2 Wash−out sponges being introduced

" Push two or three water−soaked wash−out sponges into the

wash−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".

å The water forces the concrete in the delivery line towards
the end of the delivery line.

" Top up the water in the hopper in good time (on longer delivery
lines) before air is sucked in.

" Pump until the wash−out sponges exit at the end of the delivery
line. Take care to ensure that the water flowing behind it does
not run into the formwork.

" Then switch the pump to reverse pumping so that the washing
water can flow out of the delivery line.

632 AP07_045_9712EN
 Pumpingoperations

Cleaning with an The principle of this method of cleaning is similar to that for high−
auxiliary pump pressure water cleaning. This involves, however, separating the
delivery line from the concrete pump and replacing this with an
auxiliary pump such as a high density solids pump (KOV) or a
wash−out adaptor with high−pressure water pump.

Note
Any high−pressure water pump you might be using must have a
sufficient 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 the
wash−out adaptor with high−pressure water pump.

AP07_046_9712EN 633
 Pumpingoperations

Introducing the
wash−out sponge

1 2

AP07_046_9712EN 1

1 Prepared pipe section for cleaning

2 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 close
the port or fit the pipe section prepared for cleaning into the
delivery line.

" When using a high−pressure water pump, push two or three

water−soaked wash−out sponges into the wash−out port and
then connect it to the delivery line.

" Connect the water for the auxiliary pump or high−pressure

water pump.

" Switch the pump to Forwards pumping".

å The water forces the concrete in the delivery line towards
the end of the delivery line.

" Pump until the wash−out sponges exit at the end of the delivery
line. Take care to ensure that the water flowing behind it does
not run into the formwork.

634 AP07_046_9712EN
 Pumpingoperations

6.9.3 Hopper, delivery One possible method of cleaning the hopper, the delivery cylinder
cylinder and and the S transfer tube is described below.
S transfer tube

Note
If the machine is fitted with an agitator safety cutout, the agitator is
halted and the transfer tube no longer switches over as soon as you
open the grille. In addition, the delivery pistons return to the end
position and the concrete pump halts. You must close the grille to
restart the concrete pump.

Danger
In no event should you insert the water hose, the spray gun or other
objects through the grille into the hopper to spray out the delivery
cylinders. Such objects may be trapped by the transfer tube as it
switches over and become damaged. The objects may be caused to
fly about, thereby causing an injury to you or other persons.

Drain off the leavings

ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ
ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ
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ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ

AP07_047_9904EN 1

Lay the sheet down

" Place the Putzmeister leavings sheet beneath the hopper.

" Open the hopper flap beneath the hopper and let the leavings
flow out of the hopper.

AP07_047_9904EN 635
 Pumpingoperations

" Switch the pump over to reverse pumping.

å This pumps the leavings out of the delivery cylinders into
the hopper and thus out of the hopper opening.

30000500

Hoisting the concrete away

Caution
You may only hoist a maximum of 0.5m 3 concrete (approxi
mately1200kg) using the Putzmeister leavings sheet.

" Hoist away the concrete in the Putzmeister leavings sheet.

636 AP07_047_9904EN
 Pumpingoperations

Spray out delivery

cylinder
ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ
ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ
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ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ

AP07_047_9904EN 2

Spray out the transfer tube and delivery cylinder with the concrete pump running slowly
in 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 as
you do this (see the Mark water hose" section).

AP07_047_9904EN 637
 Pumpingoperations

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 the
marking, for several minutes, until only clean water runs out.
å 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 with
concrete.

638 AP07_047_9904EN
 Pumpingoperations

Check sealing gap You should check the seal gap between the transfer tube and wear
ring following cleaning. The gap S" must be 1.5 to 2mm, if not the
transfer tube must be readjusted.

Maintenance card: Adjusting the S transfer tube

1 2 3 4
AP07_047_9904EN 4

1 Transfer tube
2 Thrust ring
3 Wear ring
4 Spectacle wear plate

" Check the gap S" between the transfer tube and wear ring.

Note
The gap between the transfer tube and the wear ring must be 1.5 to
2mm.

AP07_047_9904EN 639
 Pumpingoperations

Cleaning the gap After each pumping operation, you must clean the transfer tube
between the transfer bearing thoroughly to prevent any concrete encrustation in the
tube bearing and the transfer tube bearing.
S transfer tube

1 2 3

5 4

AP07_068_1007EN 1

No. 0 Designation
1 S transfer tube
2 Areas that must be cleaned
3 Pressure connection
4 Lubrication points
5 Transfer tube bearing

" Carefully spray out the areas to be cleaned(2) on the pressure

connection(3) and on the transfer tube bearing(5).

" Immediately after cleaning, use the lubrication point

provided(4) to grease the transfer tube bearing(5).
å Grease is visible between the S transfer tube(1) and
transfer tube bearing(5).

640 AP07_068_1007EN
 Pumpingoperations

6.9.4 Post-cleaning Once the delivery line, hopper, delivery cylinders and S transfer
procedure tubehave been washed out, you must thoroughly rinse down all
other parts of the machine that have come into contact with con

crete. Concrete that is not washed off immediately can attack the
paint, especially if aggressive concrete additives have been used.

Caution
The delivery line, water box, water tank and water pump must be
drained fully if there is a risk of freezing. The water box must also be
drained at normal temperatures during longer breaks in pumping,
e.g. overnight and at weekends.
Leave the water outlet open afterwards.

Danger of explosion
Atomized preserving agents are highly explosive. Keep away from all
sources of ignition whilst spraying.

Danger of poisoning
Cleaning agents, solvents or preserving agents sprayed in air can
enter the lungs and trigger serious damage to health. You should,
therefore, always wear respiratory protection during this work.

AP07_048_1007EN 641
 Pumpingoperations

" Clean all seals and the seal seats.

" Grease the seals before replacing them.

" Clean the remaining parts of the machine by rinsing down

withwater.

" At the lubrication point provided, grease all of the bearing

points in the hopper area immediately after washing it out.
å 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 agent

or release agent.

642 AP07_048_1007EN
 Operation

6.10 Measures for If you are placing concrete pumps or placing booms into storage
preserving the value formore than four weeks, you must carry out the following measures
of concrete pumps in order to preserve their value. Carry out these measures at least
and placing booms every 3months. If required due to the climatic conditions to which
in storage the stored machine is exposed, you must carry out these measures
at shorter intervals.

Checklist for value preservation measures for concrete pumps and placing booms
in storage

Assembly Action
Document the date that the machine is placed into storage and
Documentation
the value 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.
Disconnect the battery.
For DEUTZ motors with an EMR3electronic engine governor,
seethe procedure for switching off on page645.
Electrical system Check the battery charge state and charge the battery
ifnecessary.
Connect the central control unit (CCU) to a supply voltage at
six
monthly intervals.
Empty the water tank and the water lines. Leave the drainage
openings open.
Water Drain the water box. Leave the drainage openings open.
Closethe water box cover.
Drain the high
pressure water pump.
Check that the coolant contains sufficient anti
freeze and
corrosion inhibitor.
Engine
Cover any exhaust pipes that exit upwards.
Detach exhaust pipes from the turbocharger.

BP07_797_1006EN 643
 Operation

Assembly Action
Lubricate the arm assembly.
Boom Detach the end hose.
Grease all exposed piston rods with Vaseline.
Check the function of hose reels on machines larger than an M52:
Support
Fully extend the front support legs 10times.
Grease all exposed piston rods with Vaseline.
Concrete pump
Grease the interior surfaces of the delivery cylinder with Vaseline.
Grease the untreated surfaces of mechanical parts (race ring,
Truck mixer drum rollers, etc.) with Vaseline.
Close the full lock on the intake hopper.
Open and lock the hopper flap.
Hopper
pp Close the spray guard.
Spray the hopper area with barrier agent.
Vehicle superstructure Grease all exposed piston rods with Vaseline.

644 BP07_797_1006EN
 Operation

Caution
The instructions in this warning notice apply to DEUTZ motors with
an electronic engine governor (EMR3).

You may only disconnect or switch off the battery once the control
unit has completed its rundown time (approximately 20seconds).
Interrupting this rundown 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 instructions
below:
 Only switch off the engine using the ignitionstarter switch.
 Do not unplug the control unit connector when the power supply
isswitched on (ignitionon).
 If maintenance work is to be carried out on the machine (e.g.
electrical welding work), you must always disconnect all plugin
connections from the control unit.

Putzmeister will not accept warranty claims for engine damage and
operating errors that result from a failure to switch off the engine
according to the instructions.

BP07_797_1006EN 645
 7 Maintenance

In this chapter you will find information on maintenance work which is

necessary for the safe and efficient operation of the machine.

Following the general maintenance information, you will find the

maintenance cards necessary for this machine. The table of contents
includes a summary of the maintenance cards in numerical order,
you will find an alphabetical summary in the Index of key words
under the entry for Maintenance cards".

We should like here to emphasise expressly that all prescribed

checks, inspections and preventative maintenance work must be
conscientiously carried out. Otherwise, we will refuse to accept any
liability or to honour the warranty. Should you ever be in any doubt,
our After Sales Department is always ready to give you advice and
assistance.

BP09_001_9405EN
 Maintenance

7.1 Daily tasks You must carry out daily checks, function checks and maintenance
tasks so that your machine remains fully functional and is safe in
operation. 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 checks
must be carried out at the beginning of each new shift in the case of
machines in continuous operation.

Caution
You must rectify (or have rectified) any defects immediately you
discover them during your checks.

7.1.1 Daily visual checks You must lubricate your machine and check it each time before you
start to use it.

Assembly Checking Criterion

available and in a fully functioning
Safety devices
condition
General
Lubrication points sufficient lubrication

Engine Oil level sufficient

Agitator gearbox Oil level sufficient

Oil level sufficient

Hydraulic system Condensation in the hydraulic fluid
drain off if present
reservoir
Radiator Contamination sufficient cooling possible

Spacer flange securing wire undamaged securing wire

The piston rods must be completely

Water level
Water box covered
no hydraulic fluid or concrete in the
Water contamination
water box
Inner wall and wear ring no mechanical wear
Transfer tube
Spectacle wear plate no mechanical wear

Pipes no leaks or fractures

Centralized lubrica

lubrica
tion system Grease gun sufficient grease reserve

designed for the delivery pressure, laid

Delivery line Suitability and wear according to the rules of technology,
wall thickness sufficient

Compressor Oil level sufficient

AP09_002_0308EN 71
 Maintenance

7.1.2 Function check You must always check all the control and monitoring functions plus
the 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

Agitator cut−out fully functional

Hydraulic system
Drive 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

72 AP09_002_0308EN
 Maintenance

7.1.3 When pumping 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 pressure no cement−coloured oil and grease
connection mixture or slurry cement may escape
from the bearings
Hopper Mixer shaft bearings and seal

Instruments Monitor all in the normal range

7.1.4 After every job You should carry out the following service operations and checks
after every job.

Assembly Activities and checks Criterion

Cleaning
General
All lubrication points sufficient lubrication

Water box Drain off water

Check inner wall and wear ring no mechanical wear

Transfer tube
Check sealing gap gap < 1mm

Coupling and seal ring on pressure

Delivery line grease
pipe

AP09_002_0308EN 73
 Maintenance

7.2 Maintenance work The maintenance tasks as required" must be carried out if faults are
discovered during the daily checks. Other maintenance work is re

quired at regular intervals. The maintenance cards describe all the
maintenance tasks which are within your means to carry out. You can
find these further on in this chapter. The maintenance tasks have
been listed in the tables according to their time intervals.

7.2.1 As required You must carry out the work described below if you determine that it
is 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
Tighten bolts on the spacer flange
Core pump
Replace delivery pistons
Measure the wall thickness
Adjust the transfer tube
Replace the spectacle wear plate
Transfer tube
Tighten the clamping bolts on the switch lever
Replace switching shaft bearings and seals
Pressure connection − replace bearings and seals
Replace bearings and seals
Agitator
Full transmission oil change
Check wear
Delivery line
Check coupling to pressure pipe

74 AP09_001_0902EN
 Maintenance

7.2.2 Regular maintenance Regular maintenance tasks must be carried out in addition to the
tasks daily visual inspections and function checks and servicing oper

ations.

Caution
The maintenance intervals are specified for normal wear. You will
have to shorten the maintenance intervals accordingly if you are
pumping very abrasive media.

Weekly You must tighten the fastening bolts on the vibrator and clean the
compressor once a week.

Every 500 hours The following tasks must also be carried out after 500 operating
of operation hours, but at least once a year. In addition, a subject expert should
inspect the pump and the delivery line.

Assembly Activity / Maintenance card

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
Check the agitator cut−out (function check)
Hydraulic system
Clean hydraulic fluid radiator and check function
Check temperature sensor
Check hydraulic accumulator, top up and adjust if necessary
Centralized
Check centralized lubrication system
lubrication system
Check that all magnetic switches are positioned and functioning
Electrical system
correctly

AP09_001_0902EN 75
 Maintenance

Assembly Activity / Maintenance card

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
Check tightening torque of the switch lever clamping bolts
Transfer tube
Check the ball cups for the switch cylinders
Check the switching shaft bearings and seals
Check the pressure connection bearings and seals
Change transmission oil
Agitator
Check mixer shaft bearings
Full oil change in accordance with manuacturer’s Operating Instructions
Compressor Clean air filter (wash out) in accordance with manufacturer’s Operating
Instructions
Clean intake filter
Water pump
Replace the HW520 and WP50 plastic rollers
Maintenance information in accordance with manufacturer’s Operating
Engine
Instructions

76 AP09_001_0902EN
 Maintenance

7.3 Residual risks during maintenance, inspection and repair work

7.3.1 Personal protective See the "Safety regulations" chapter for personal protective equip

equipment ment requirements.

Danger
Risk of serious physical injury if personal protective equipment is
notworn. Always wear your personal protective equipment during
maintenance, inspection and repair work. Safety helmet and safety
footwear are a basic requirement. Other personal protective equip
ment is required as listed in the "Safety regulations" chapter.

7.3.2 Personnel Maintenance, inspection and repair work must only be carried out
requirements byqualified personnel. "Qualified personnel" means those who have
completed specialist training for carrying out such work. This training
qualifies them to carry out the activity concerned.

7.3.3 Auxiliary devices Adequate workshop equipment is absolutely necessary for carrying
out maintenance, inspection and repair work.

If you do not have qualified personnel, suitable workshop equipment

etc. available, you should commission the manufacturer’s After Sales
Department with the maintenance of your machine.

BP09_020_1108EN 77
 Maintenance

7.3.4 Residual risks During maintenance, inspection and repair work, there are
particularrisks of an accident, because for certain activities,
protective devices must be removed, for example. There follows
alist of residual risks in particular, which may be present during
maintenance, inspection and repair work.

Danger
There is a risk of falling when working above the ground or floor.
Youshould therefore always ensure that you are secure by using
safety harnesses, railings or walkway barriers. Never use machine
parts as climbing aids. Keep all handgrips, steps, railings, platforms
and ladders free from dirt, snow and ice.

Danger
In the area between the mixer drum and frame, there is a risk of
being pulled in, crushed or injured by shearing. Working in this area
is only allowed if the mixer drum is secured with the mixer drum
holder. Read the operating instructions from the truck mixer manu
facturer for information about this.

Danger
Risk 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 safety
data sheets produced by the manufacturer of the functional fluids.

Danger
Risk 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 surfaces
withheatresistant materials.

78 BP09_020_1108EN
 Maintenance

Danger
Risk of injury from pressurised hydraulic fluid. Put the machine out
ofservice before starting maintenance, inspection and repair work.
Depressurise the hydraulic system. Dump pressure from the accu
mulator.

Danger
Risk of injury from compressed air. Put the machine out of service
before starting maintenance, inspection and repair work.
Depressurise the compressed air system.

Danger
Risk of injury from whipping hydraulic hoses. Mechanically pre
stressed hydraulic hoses may lash out when loosening the threaded
union. Wear your personal protective equipment. Secure the
hydraulic hoses tightly in place when loosening the threaded unions.

Danger
Risk of injury from the machine starting unexpectedly. Before starting
maintenance, inspection and repair work, put the machine out of
service and secure it against unexpected restarting (e.g. remove
ignition key and put it in your pocket, place a warning plate on the
controls). If this is not possible, ask someone to stand guard who
can prevent the machine from starting up unexpectedly.

BP09_020_1108EN 79
 Maintenance

7.4 General tightening Tightening torques depend on bolt grade, thread friction and bolt
torques head bearing area. The values given in the following tables are for
guidance. These values should only be used if no other values are
specified in the relevant chapters of the Operating Instructions or in
spare parts sheets.

Caution
You must always use bolts of the same size and property class when
you have to replace bolts. Bolts with adhesive in the locking threads
and self−locking nuts must always be replaced after removal.

7.4.1 Set screws and nuts You will find the maximum tightening torques for set screws and nuts
in spare parts list.

710 BP09_003_1102EN
 Maintenance

7.4.2 Flared screwed joint, After each time the joint is undone, the union nut must be tightened
reassembly again securely without excessive force.

Flared screwed joints

External diam- MA [Nm] External diam- MA [Nm]
eter / Type eter / Type
6 L 20 16 S 130
8 L 40 18 L 120
10 L 45 20 S 250
L 55 25 S 400
12
S 80 30 S 500
15 L 70 38 S 800
* RAD = pipe external diameter
* MA = tightening torque

Note
Hold threaded connection fast against turning with wrench.

10400100

Tightening flared screwed joint

7.4.3 Profiled ring joint, After each time the joint is undone, the union nut must be tightened
reassembly again securely without excessive force to ensure that the joint is
tight.

BP09_003_1102EN 711
 Maintenance

7.5 Functional fluids This section lists all the functional fluids used in your machine.

Caution
Never use hydraulic fluids or lubricants with additives such as
molybdenum. Such additives can attack the bearings.

7.5.1 Hydraulic fluid 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).

Please see the machine card to find out what the initial filling was in
your machine.

Danger
Never mix hydraulic fluids of different types, i.e.do not mix biologi
cally degradable hydraulic fluids with mineral hydraulic fluids etc.

712 BP09_004_0502EN
 Maintenance

Note
Please only use a hydraulic fluid complying with the classification
and requirements standards specified in the lubricant recommenda
tion for topping up or a full fluid change. HEES synthetic esters and
HFC aqueous solutions from different manufacturers must not be
mixed together without prior approval from the manufacturers con
cerned.

When hydraulic fluids of different viscosity grades are mixed, the

new viscosity is determined by the mix ratio. Loss of quality is poss
ible if hydraulic fluids from different manufacturers are mixed. For this
reason, you must always consult the manufacturer before mixing
fluids.

When the hydraulic fluid is changed, some 1015% of the old hy
draulic fluid remains in the system (in cylinders, pumps, lines, etc).

Take note of VDMA’s changeover guidelines and manufacturer’s in

structions if you are changing over your fluid. Please contact the
manufacturers concerned if you have any queries regarding the suit
ability and miscibility of hydraulic fluids.

BP09_004_0502EN 713
 Maintenance

7.5.2 Level of contaminant Level of contaminant 19/16/12 in accordance with ISO4406 is speci

fied for lubrication and the hydraulic system. You can find the level of
contaminant of the initial filling from the test report on the machine
card.

7.5.3 Lubricant analysis We can carry out a lubricant analysis for you should you discover
that 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 (material
no.257260.004). We will carry out a lubricant analysis to determine
the cause.

7.5.4 Storage of lubricants Do not store oils and greases in the open air. Water may be ab

sorbed through the bung hole in the event of changes in the expo

sure to the weather.

Only ever store the barrels lying on their side and supported on
timber blocks, with the bung hole facing upwards.

Environmental protection
You must carefully collect all functional fluids, e.g.used oil (including
biologically degradable oils), filters and auxiliary materials and dis
pose of them separately from other waste. You must keep used oils
of various types separate in order to keep disposal costs as low as
possible.

Observe the national and regional regulations applicable to your

area. Only work with waste disposal companies who are approved
by the responsible authorities.

714 BP09_004_0502EN
 Maintenance

7.6 Lubricant You will find suitable lubricants and hydraulic fluids in the tables
recommendation below. Putzmeister accepts no liability for the quality of the lubricants
and hydraulic fluids listed or for changes in quality made by the
lubricant manufacturer without changing the grade designation.

Note
Please use only Putzmeister hydraulic fluid, material no. 239879002,
when you are topping up the hydraulic fluid or carrying out a full fluid
change if your machine was filled with non−readily flammable hy
draulic fluid in the works (HFC as specified in the 7th Luxembourg
Report).

Please use only Putzmeister hydraulic fluid, material no. 239693000,

when you are topping up the hydraulic fluid or carrying out a full fluid
change if your machine was filled with a synthetic ester in the works.

Putzmeister accepts no liability for damages caused by mixing fluids

from different manufacturers.

You must first consult Putzmeister Department APS if you wish to use
hydraulic fluids with viscosity grades other than VG46 (e.g. at higher
ambient temperatures).

The proportion of residual fluid must not be greater than 2% after a

fluid change from HLP to HEES. This means that a flushing filling with
the full quantity of the new hydraulic fluid must be carried out. In
addition, for reasons of gasket compatibility, a fluid change must
becarried out no later than 6months after the machine is commis
sioned. It should also be noted, at this point, that all filters must
bechanged after 50 hours of operation, since deposits may be
dissolved and transported to the filters by the new fluid.

BP09_016_0708EN 715
 Maintenance

Caution
The following points must be complied with in order to prevent
damage:
 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 and
allow 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.

Danger
Never mix hydraulic fluids of different types, i.e. do not mix biologi
cally degradable hydraulic fluids with mineral hydraulic fluids etc.

716 BP09_016_0708EN
 Maintenance

7.6.1 Oils
Agitator Slewing gear Transfer
Rotor gearbox
gearbox transmission gearbox
Requirements
DIN 51 517 DIN 51 517 DIN 51 517
standard
Characteristics synthetic mineral mineral see spare
p p
parts
Viscosity grade, sheet
CLP 220 CLP 220 CLP 220
NLGI Class
Material no. 295246.006 000101.006 000101.006

Note
Truck transmissions, truck engines and independent power units are
filled by the respective manufacturer. Maintenance only in accord
ance with the manufacturer’s specifications.

BP09_016_0708EN 717
 Maintenance

7.6.2 Greases
Greasing Centralized Greasing the pump
(manual) lubrication system tube in rotor pumps
Marking in
accordance K2K−30 K1K−30 
with DIN 51 502
Requirements
DIN 51 825 DIN 51 825 
standard
Characteristics mineral, lithium soap 
Viscosity grade, NLGI Class 2 NLGI Class 1

NLGI Class DIN 51818 DIN 51818
Material no. 360000.009 360001.008 290207.008

Note
We recommend the following grease, rather than those specified in
the lubricant table, should you wish to fill the centralized lubrication
system with a low temperature grease in extremely cold conditions:
Marking in accordance with DIN51502: KE2G−60, NLGI Class2

718 BP09_016_0708EN
 7.6.3 Hydraulic fluids
BP09_017_0905EN

Category Mineral oil Synthetic ester Aqueous solutions

Type HLP HEES HFC
Classification
DIN 51502
ISO 6743/0
Requirement
DIN 51524 Part 2  
ISO 6743 Part 4  
VDMA 24318 24568 24317/24320
Others   7th Luxembourg Report
Viscosities
DIN 51519
ISO 3448
2
mm /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
 biodegrades quickly non−readily flammable
characteristics
Initial filling
Material no. 490984 000171.007 279845.009 484527 239879.002
BECHEM HYDROSTAR FUCHS HYDROTHERM
Manufacturer 

Maintenance
HEES46 46M
Changeover guidelines
VDMA  24569 24314
7 — 19
 Maintenance cards

In this section you will find the maintenance cards necessary for this
machine. The table of contents includes a summary of the mainten

ance cards in numerical order, you will find an alphabetical summary
in the Index of key words under the entry for Maintenance cards".

BP09_013_1205EN 721
722
 Maintenancecard
00−001
Page 1 of 2

00–001 Visual checks This maintenance card describes visual checks that you must
carryout before commencing any maintenance work. You will find
the maintenance intervals in the maintenance summary at the start
ofthis chapter.

Note
There 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 maintenance, inspection
and repair work" at the start of the chapter entitled "Maintenance"
(i.e. this chapter).

See also the maintenance cards:

Filter change
Hoses

No special tools required.

Danger
Inspect the electrical cables particularly closely and carefully.
Thereis a danger of flash overs from defective cables, particularly
when there is high air or ambient humidity. There is a danger of fire
and explosion through the formation of sparks when the machine is
used in a potentially explosive atmosphere.

WK00_001_1109EN 723
 Maintenancecard
00−001
Page 2 of 2

General The general visual inspections listed below should always be carried
out before any maintenance work, and also each time before starting
work with the machine.

" Check the fill levels of the functional fluids.

" Check that all safety equipment is available and in a fully

functioning condition.

Electrical system Should you locate any damage to the electrical system, you must
have the damage rectified immediately by a qualified electrician.

" Check that all electrical connections are secure and free from
corrosion.

" Check that the electrical cables have no breaks.

" Check the insulation on the electrical cables.

Hydraulic system Timely detection and rectification of damage to the hydraulic system
can prevent lengthy downtimes and high repair costs.

" Check that the displays on the vacuum meter of the suction
filters are still in the green range. The suction filters must be
replaced if the displays are in the red range.
Maintenance card: Filter change

" Check the contamination indicators on the boom filters.

Thefilters are in order if the red button remains depressed.
Thefilter must be replaced if the red button pops out.
Maintenance card: Filter change

" Check the fluid cooler for contamination and deposits.

" Check all hydraulic hose lines for leaks.

Maintenance card: Hoses

" Check all screwed hydraulic screw
couplings for tightness

andleaks.
Maintenance card: Hoses

724 WK00_001_1109EN
 Maintenancecard
03−002
Page 1 of 2

03–002 Function checks This maintenance card describes the inspection of machine func

tions. The inspections are carried out with the machine running. You
will find the service intervals in the maintenance summary at the start
of this chapter.

Note
There 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 maintenance, inspection
and repair work" at the start of the chapter entitled "Maintenance"
(i.e. this chapter).

No further maintenance cards required.

The following special tools are required:

Pressure gauge and connections for the tapping points shown in the
hydraulic circuit diagram

Note
Only qualified personnel authorized by us may carry out work on the
hydraulic system. Notify the Putzmeister After Sales department or
the dealer/agent who looks after you immediately should you find
any irregularities.

" Measure the pressures generated by the pumps, using the

measuring equipment specified directly on the pumps, and
compare your results with the values specified in the test
reading.

" Check the proper functioning of the pressure−relief valves in

the high pressure circuit and the pressure accumulator.

WK03_002_1109EN 725
 Maintenancecard
03−002
Page 2 of 2

726 WK03_002_1109EN
 Maintenancecard
03−010
Page 1 of 4

03–010 Changing the hydraulic This maintenance card describes a full fluid change on the hydraulic
fluid system and cleaning the fluid sump in the hydraulic fluid reservoir.

Note
There are specific risks of an accident associated with maintenance,
inspection and repair work. For this reason, read the chapter "Safety
regulations" 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 checks
Filter change
Hoses

No special tools required.

Note
Cleanliness is of the utmost importance in the maintenance of hy
draulic systems. Prevent any type of dirt and contamination from
entering the system. Even small particles of dirt may cause valves to
be scored, pumps to seize and throttle and control bores to become
blocked.

Hydraulic fluid barrels must stand for some time before the fluid is
removed from them. Do not roll the barrels to the tapping point.
Clean bungs and filler lids as well as the area around them before
opening 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 than
necessary.

WK03_010_1109EN 727
 Maintenancecard
03−010
Page 2 of 4

Preparation The following tasks must be carried out before starting the full fluid
change:

" Switch off the remote control.

" Switch off the pump.

" Switch off the engine/motor.

" Dump the fluid pressure completely.

Danger
Pressure stored in accumulators must be dumped.

" Secure the machine against unauthorized starting.

" Secure your working area and fix information plates to the
locked controls and setting devices.

Full fluid change

10300400

Draining off the fluid

" Open the fluid drain cock on the hydraulic fluid reservoir and
let the hydraulic fluid drain into a suitable container.

728 WK03_010_1109EN
 Maintenancecard
03−010
Page 3 of 4

Environmental protection
All functional fluids and operating materials, e.g. oils (including bio
logically degradable oils), filters and auxiliary materials must be
carefully collected and disposed of separately, both from each other
and from other waste. Different categories of oil must also be kept
separately from each other. Nationally and regionally applicable dis
posal regulations must be observed for these materials.

Clean fluid sump

" Open the cleaning port on the side of the hydraulic fluid reser

voir.

" Remove all filter elements.

Maintenance card: Filter change

" Wipe out all the openings with a lint−free cloth. Wipe as far into
the reservoir as possible when doing this.

" Change all filters and refit the filter elements.

" Replace any defective hoses.

Maintenance card: Hoses

" Check the seals on the cleaning port and replace these if they
show signs of being defective.

" Close the fluid drain cock and the cleaning port again.

" Check all threaded unions and tighten where necessary. Check
all flared screwed joints.
Maintenance card:Hoses

WK03_010_1109EN 729
 Maintenancecard
03−010
Page 4 of 4

10300500

Filling the reservoir

" Fill the reservoir with new fluid.

Note
Only 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. Check
all flared screwed joints.
Maintenance card: Hoses

" 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 have
removed.

730 WK03_010_1109EN
 Maintenancecard
04−002
Page 1 of 4

04–002 Hydraulic hoses This maintenance card describes how to check and replace the
hydraulic hoses. You will find the maintenance intervals in the main

tenance summary at the start of this chapter.

Note
There 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 maintenance, inspection
and repair work" at the start of the chapter entitled "Maintenance"
(i.e. this chapter).

No further maintenance cards required.

No special tools required.

MA The tightening torques can be found in the corresponding

Spareparts list.

Note
Check all hydraulic hoses (including hose fittings) with the machine
running.
You must replace the hydraulic hoses at the slightest sign of damage
or even mere indications of threatened damage.

WK04_002_1110EN 731
 Maintenancecard
04−002
Page 2 of 4

Environmental protection
All functional fluids and operating materials, e.g. oils (including bio
logically degradable oils), filters and auxiliary materials must be
carefully collected and disposed of separately, both from each other
and from other waste. Different categories of oil must also be kept
separately from each other. Nationally and regionally applicable dis
posal regulations must be observed for these materials.

Leaking
hydraulic hoses

10400800

Check hydraulic hoses

Dark and moist patches on the fitting are external signs of incipient
damage. Check:
− the hydraulic hoses for kinks, cracks or a porous surface and
− whether the hydraulic hoses have been laid without restrictions.

Note
Beware of strong sunlight, the action of heat and the effects of
chemicals.

732 WK04_002_1110EN
 Maintenancecard
04−002
Page 3 of 4

Replacing The procedure for replacing hydraulic hoses is as follows:

hydraulic hoses
" Shut down the machine and secure against unauthorized
starting.

" Fully dump any (residual) pressure in the hydraulic system.

Danger
Hydraulic hoses may be mechanically pre−stressed. There is a risk
of injury from whipping hoses.

" Take care when undoing the joints.

" Close the connection points with a plug immediately you have
removed the old hydraulic hoses. No dirt may enter the hy

draulic circuit and the hydraulic circuit must not run empty.

Danger
Hydraulic hoses should not be more than six years old, including a
storage time of two years. Take note of the date of manufacture on
the 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 after
fitting new hydraulic hoses.

WK04_002_1110EN 733
 Maintenancecard
04−002
Page 4 of 4

Flared screwed joints

10400100

Tightening flared screwed joint

" Check whether the flared screwed joints are tight.

Note
You may only tighten leaking flared screwed joints with the permitted
tightening torque. Tighten the flared screwed joints until you clearly
feel an increase in the force required if you do not have a torque
wrench available. You must replace these flared screwed joints if
leaking continues.

The tightening torques can be found in the table
Flared screwed

joints" at the start of this chapter.

734 WK04_002_1110EN
 Maintenancecard
04−005
Page 1 of 2

04–005 Vacuum meter This maintenance card describes how to replace the vacuum meter
and how to remove the packing piece. You will find the service inter

vals in the maintenance summary at the start of this section.

Note
There 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 maintenance, inspection
and repair work" at the start of the chapter entitled "Maintenance"
(i.e. this chapter).

No further maintenance cards required.

No special tools required.

Note
Replace the vacuum meter if it is mechanically damaged or if the
display is incorrect, e.g. there is an indication although the machine
is not running.

Caution
You must remove or open the packing piece once you have fitted the
new vacuum meter.

WK04_005_1109EN 735
 Maintenancecard
04−005
Page 2 of 2

" 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 piece
or piercing the rubber stopper, depending on the design.

736 WK04_005_1109EN
 Maintenancecard
04−013
Seite 1 von 6

04–013 Changing the pressure filter This maintenance card describes how to change the pressure filter
element element. You will find the maintenance intervals in the maintenance
summary at the start of this chapter.

Note
There 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 maintenance, inspection
and repair work" at the start of the chapter entitled "Maintenance"
(i.e. this chapter).

No further maintenance cards required.

No special tools required.

MA The tightening torques can be found in the corresponding

Spareparts list.

Note
Cleanliness is of the utmost importance in the maintenance of hy
draulic systems. Prevent any type of dirt and contamination from
entering the system. Even small particles of dirt may cause valves to
be scored, pumps to seize and throttle and control bores to become
blocked.

Hydraulic fluid barrels must stand for some time before the fluid is
removed from them. Do not roll the barrels to the tapping point.
Clean bungs and filler lids as well as the area around them before
opening.

If possible, you should use a charging set to fill up the hydraulic sys
tem. Never leave the tank lid open longer than necessary.

WK04_013_1109EN 737
 Maintenancecard
04−013
Seite 2 von 6

Caution
Filter elements freely available on the market have too low a flow
rate. 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 always
be replaced.

Environmental protection
All functional fluids and operating materials, e.g. oils (including bio
logically degradable oils), filters and auxiliary materials must be
carefully collected and disposed of separately, both from each other
and from other waste. Different categories of oil must also be kept
separately from each other. Nationally and regionally applicable dis
posal regulations must be observed for these materials.

Preparation 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.

Danger
Pressure stored in accumulators must be dumped.

" Secure the machine against being started up by unauthorized

persons  if you have any key
operated switches, remove the
key and disconnect the supply voltage.

" Secure your working area and fix information plates to the
locked controls and setting devices.

738 WK04_013_1109EN
 Maintenancecard
04−013
Seite 3 von 6

Checking 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.

Note
The filter element is OK if the red button remains depressed.

The filter element must be replaced if the red button pops out again.

WK04_013_1109EN 739
 Maintenancecard
04−013
Seite 4 von 6

Changing

WK04_013_1109EN 2

No. 0 Designation
1 Filter element
2 Filter housing

Caution
The filtering process causes dirt and contamination particles to
accumulate in the filter housing. You must therefore clean the filter
housing thoroughly before refitting the new filter element, as other
wise the new filter element will rapidly become clogged again.

740 WK04_013_1109EN
 Maintenancecard
04−013
Seite 5 von 6

" 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.

Note
Before fitting new filter elements, you must check all Orings and
other seals on the filter elements and replace them if damaged.

" Screw the filter housing back on.

Note
Check the level of the contamination indicator. Always refit the pro
tective lid on the contamination indicator each time this is checked.

WK04_013_1109EN 741
 Maintenancecard
04−013
Seite 6 von 6

742 WK04_013_1109EN
 Maintenancecard
06−023
Page 1 of 6

06–023 Delivery piston replacement This maintenance card describes how to replace the delivery
pistons. You will find the maintenance intervals in the maintenance
summary at the start of this chapter.

Note
There are specific risks of an accident associated with maintenance,
inspection and repair work. For this reason, read the chapter "Safety
regulations" 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).

No further maintenance cards required.

No special tools required.

Note
You must rectify damage to the delivery pistons immediately.
Putzmeister accepts no warranty claims for damage to the machine
resulting from failure properly to observe the maintenance regula
tions.

Danger
Secure the working area. Affix warning notices to the blocked control
and setting devices.

WK06_023_1109EN 743
 Maintenancecard
06−023
Page 2 of 6

You will have to start and stop the machine a number of times as you
replace the delivery pistons . The operations necessary for this are
described below and must be carried out conscientiously.

Shutting down Proceed as follows to shut down the machine:

the machine
" Set the output to zero.

" Ensure that the Reverse pumping toggle switch on the control
cabinet 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 on
the pressure gauge that the fluid pressure in the accumulator
has declined.

Danger
Dump the accumulator pressure completely on machines with accu
mulators.

Starting up The procedure for starting up the machine is as follows:

the machine
" Set the throttle to one−third.

" Start up the engine.

" Wait until the engine has reached a steady engine speed.

Caution
Do not switch the pump on until you are called upon to do so. You
should also start up the pump quite slowly each time, checking that
the piston travel direction is correct.

744 WK06_023_1109EN
 Maintenancecard
06−023
Page 3 of 6

Piston replacement Pistons are replaced from the water box.

Danger
Always shut the machine down before you reach into the water box.

1 2 3 2 4

5
10600301

1 Piston rod flange

2 Fastening bolts
3 Securing wire
4 Delivery piston
5 Spacer flange

" Shut the machine down.

" Drain the water from the water box and remove the water box
cover.

" Start the machine up.

" Switch the machine on and allow the hydraulic piston of the
delivery piston to be removed to travel slowly to its end
position.

" Switch the pump off once the transfer tube has switched over.
å The spacer flange will now be visible in the water box.

" Shut the machine down.

WK06_023_1109EN 745
 Maintenancecard
06−023
Page 4 of 6

Removing a piston
1

10600701

1 Fastening bolts

" Remove the wire clips from the fastening bolts and remove the
bolts 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 carefully
with a hammer.

" Remove the spacer flange, and store it in such a way that it is
protected against damage until it is reinstalled.

" Start the machine up.

" Switch the concrete pump on at a very low output.

å The piston rod flange approaches the delivery piston
slowly.

" Shut the machine down.

" Bolt the delivery piston to the piston rod flange.

746 WK06_023_1109EN
 Maintenancecard
06−023
Page 5 of 6

" Start the machine up.

" Set the toggle switch on the control cabinet to reverse

pumping.

" Switch the concrete pump on at a very low output.

å The delivery piston is withdrawn completely from the
delivery cylinder.

" Shut the machine down.

" Undo the bolted connection on the piston rod flange and
remove the old delivery piston.

" Thoroughly clean the delivery piston edge at the end of the
water box.

Caution
Do not use any hard objects or caustic cleaning agents to clean the
delivery cylinder. These could damage the chrome layer.

Fitting a piston A piston is fitted in the reverse order of the operations required to
remove 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.

WK06_023_1109EN 747
 Maintenancecard
06−023
Page 6 of 6

" Start the machine up.

" Switch the concrete pump on at a very low output.

å The new delivery piston is pushed very slowly into the
delivery cylinder.

" Switch the pump off before the fastening bolts for the delivery
piston disappear into the delivery cylinder.

" Shut the machine down.

" Undo two fastening bolts on the delivery piston.

" Start the machine up.

" Set the toggle switch on the control cabinet to reverse

pumping.

" Switch the concrete pump on at a very low output.

å The piston rod flange is drawn back.

" Switch the pump off once the spacer flange fits between the
piston rod flange and the delivery piston.

" Shut the machine down.

" Insert the spacer flange and fasten all the bolts.

" Tighten the bolts with the specified tightening torques and
secure them with a stainless steel wire.

Note
Replace the second delivery piston in the same way.

" Fasten the water box cover on the water box and fill the water
box with water.

" Then carry out a test run.

748 WK06_023_1109EN
 Maintenancecard
07−069
Page 1 of 6

07–069 Replacing the transfer tube This maintenance card describes how to replace the transfer tube
bearing bearing. You will find the maintenance intervals in the maintenance
summary at the start of this chapter.

Note
There are specific risks of an accident associated with maintenance,
inspection and repair work. For this reason, read the chapter "Safety
regulations" 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).

No further maintenance cards required.

No special tools required.

MA The tightening torques can be found in the corresponding

Spareparts list.

Danger of crushing
A pressurized hydraulic system may cause the machine to move
suddenly, which may result in you being seriously injured if you are
working on the machine. To avoid risk, shut the machine down and
secure it against unauthorized or accidental starting.

Caution
Use only suitable lifting equipment for lifting components.

Note
Wear parts must be replaced in the event of one of the following:
 Severe wear is visible
 Concrete is seeping out

WK07_069_1109EN 749
 Maintenancecard
07−069
Page 2 of 6

When maintenance work is carried out, the machine must have been
shut down. The operations necessary for this task are described
below and must be carried out conscientiously. Perform all machine
functions using the remote control.

Shutting down Proceed as follows to shut down the machine:

the machine
" Switch off the engine.

" Dump the pressures completely.

Danger
Dump the accumulator pressure completely in systems with pressure
accumulators.

Starting up Proceed as follows to start up the machine:

the machine
" If there is a throttle, set it to one third.

" Start up the engine.

" Select a low output.

" Switch the pump on.

750 WK07_069_1109EN
 Maintenancecard
07−069
Page 3 of 6

Removing the transfer The S transfer tube is mounted in the transfer tube bearing in the
tube bearing rear wall of the hopper.

" Shut the machine down.

" 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.

3 4
WK07_069_1109EN 1

No. 0 Designation
1 Hopper
2 Pressure connection
3 Pressure flange
4 Hexagon nuts

" Check the seal rings and O−rings in the transfer tube bearing
for wear and replace as required.

WK07_069_1109EN 751
 Maintenancecard
07−069
Page 4 of 6

Replacing the transfer

tube bearing gasket
set

WK07_069_1109EN 2

Bending the grooved ring to make installation easier

Caution
The mounting position for the gasket set in the transfer tube bearing
can 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.

Note
Clean the transfer tube bearing before refitting and grease the seals.
Check the lubricant bores, in particular, for proper functioning. This
is done by connecting the lubrication lines and forcing grease
through the openings.

752 WK07_069_1109EN
 Maintenancecard
07−069
Page 5 of 6

Fitting the transfer

tube bearing

WK07_069_1109EN 3

Note
Pay attention to the location of the lubrication openings when fitting
the transfer tube bearing.

" Fit the transfer tube bearing and the pressure connection again
and bolt them both in place with the pressure flange.

WK07_069_1109EN 753
 Maintenancecard
07−069
Page 6 of 6

754 WK07_069_1109EN
 Maintenancecard
07−070
Page 1 of 16

07–070 Replacing the switching This maintenance card describes how to replace the switching shaft
shaft bearing (flanged bearing (flanged bearing). You will find the maintenance intervals in
bearing) the maintenance summary at the start of this chapter.

Note
There are specific risks of an accident associated with maintenance,
inspection and repair work. For this reason, read the chapter "Safety
regulations" 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:

Adjusting the S transfer tube

No special tools required.

MA The tightening torques can be found in the corresponding

Spareparts list.

Danger of crushing
A pressurized hydraulic system may cause the machine to move
suddenly, which may result in you being seriously injured if you are
working on the machine. To avoid risk, shut the machine down and
secure it against unauthorized or accidental starting.

Caution
Use only suitable lifting equipment for lifting components.

WK07_070_1109EN 755
 Maintenancecard
07−070
Page 2 of 16

Note
Wear parts must be replaced in the event of one of the following:
 Severe wear is visible
 Concrete is seeping out

When maintenance work is carried out, the machine must have been
shut down. The operations necessary for this task are described
below and must be carried out conscientiously. Perform all machine
functions using the remote control.

Shutting down the Proceed as follows to shut down the machine:

machine
" Switch off the engine.

" Dump the pressures completely.

Danger
Dump the accumulator pressure completely in systems with pressure
accumulators.

756 WK07_070_1109EN
 Maintenancecard
07−070
Page 3 of 16

Starting up the The machine may be started up differently depending on the ma

machine chine model. When you are starting up a truck−mounted concrete
pump, proceed as follows:

" Unlock the EMERGENCY STOP button and sound the horn.

" Switch the engine on.

Caution
Do not switch the pump on until you are called upon to do so.

When you are starting up a stationary concrete pump, proceed as

follows:

" If there is a throttle, set it to one third.

" Start up the engine.

" Select a low output.

" Switch the pump on.

WK07_070_1109EN 757
 Maintenancecard
07−070
Page 4 of 16

Overview
1 2 3 4 5 6 7 8 9 10 11

14 13 12
WK07_070_1109EN 1

No. 0 Designation
1 Pulling bore for ball cup
2 Ball cup
3 Hydraulic port
4 Plunger cylinder
5 Retaining plate
6 Retaining plate fastening bolts
7 Switch lever
8 Clamping bolts with nuts
9 Disc
10 Switching shaft
11 Hexagon nut
12 Flanged bearing
13 Pulling bore for flanged bearing (two diagonally opposite
each other)
14 Fastening bolt for flanged bearing (covered)

758 WK07_070_1109EN
 Maintenancecard
07−070
Page 5 of 16

Removing the switch- The switching shaft (10) of the S transfer tube is supported in the
ing shaft bearing flanged bearing (12) in the front wall of the hopper.
(flanged bearing)

" Shut the machine down.

" Remove any lubrication lines from the retaining plate(5) and
flanged bearing(12).

WK07_070_1109EN 2

Unbolting the retaining plate

" Screw the fastening bolts(6) out of the retaining plate(5) and
remove the retaining plate(5). (You will have to replace the
lock washers on the fastening bolts (6) with new ones on reas

sembly.)

WK07_070_1109EN 759
 Maintenancecard
07−070
Page 6 of 16

Environmental protection
All functional fluids and operating materials, e.g. oils (including bio
logically degradable oils), filters and auxiliary materials must be
carefully collected and disposed of separately, both from each other
and from other waste. Different categories of oil must also be kept
separately from each other. Nationally and regionally applicable dis
posal regulations must be observed for these materials.

" 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 cylinder
from the bulkhead union.

" Catch the hydraulic fluid flowing out of the hydraulic line and
hydraulic hose.

" Seal the hydraulic line with a plug.

760 WK07_070_1109EN
 Maintenancecard
07−070
Page 7 of 16

1 2 3 4

WK07_070_1109EN 3

No. 0 Designation
1 Plunger cylinder
2 Locking plate
3 Ball cup
4 Pulling bore

Note
You can press a plunger cylinder(1) out of the ball cup(3) from the
piston side as shown. If the ball cup is worn, you can screw a bolt
into the pulling bore(4) for the ball cup and press out the plunger
cylinder 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.

WK07_070_1109EN 761
 Maintenancecard
07−070
Page 8 of 16

" 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 switching
shaft, and remove the washer.

Note
If the switch lever has a slot, this means that the switch lever is fitted
with clamping bolts, and a pulling bolt is also provided.

1 2 3

4 5 6
WK07_070_1109EN 4

No. 0 Designation
1 Clamping bolts
2 Switch lever
3 Slot
4 Pulling bolt
5 Holes for clamping bolts
6 Nuts for clamping bolts

762 WK07_070_1109EN
 Maintenancecard
07−070
Page 9 of 16

WK07_070_1109EN 5

Unscrew and remove the clamping bolts if the switch lever is

slotted

" If available, unscrew and remove the clamping bolts(1) from

the switch lever (2).

Note
One of the holes (5) for the clamping bolts(1) is also the pulling bore
for 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.

WK07_070_1109EN 763
 Maintenancecard
07−070
Page 10 of 16

1 2

WK07_070_1109EN 6

No. 0 Designation
1 Fastening bolt
2 Pulling bores (two, diagonally opposite each other)
3 Flanged bearing

" Unscrew the fastening bolt(1) from the flanged bearing (3).

" Attach suitable lifting gear to the S transfer tube.

" Press out the flanged bearing(3) by turning the two pulling
bolts supplied into the pulling bores(2).

" Check the gasket set on the flanged bearing for wear, and re

place the gasket set if required.

764 WK07_070_1109EN
 Maintenancecard
07−070
Page 11 of 16

Replacing the gasket

set in the flanged
bearing

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 cut
open the rings.

WK07_070_1109EN 765
 Maintenancecard
07−070
Page 12 of 16

WK07_070_1109EN 9

Inserting the new grooved ring

" Clean the flanged bearing.

" Grease the new gasket set.

Caution
For 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 if

necessary.

" Fit the retaining ring.

766 WK07_070_1109EN
 Maintenancecard
07−070
Page 13 of 16

Wear sleeve on
flanged bearing and
collared washer

1 2 3 4 5
WK07_070_1109EN 10

No. 0 Designation
1 Wear sleeve on the flanged bearing
2 Flanged bearing
3 Collared washer
4 Bore
5 Tab

" Bend the tab (5) on the collared washer(3) downwards.

" Place the collared washer(3) on the flanged bearing (2) so that
the tab (5) is located in the bore (4), thereby securing the
washer against rotation.

" Insert the wear sleeve(1) into the flanged bearing (2).

Note
Note the location of the lubrication bores when fitting the flanged
bearing (2).

" Grease the inside of the wear sleeve (1) with Anti−Seize AS
450 Assembly Paste" or an equivalent assembly grease.

" Locate the complete flanged bearing(2) on the switching shaft

and bolt the flanged bearing (2) in place.

WK07_070_1109EN 767
 Maintenancecard
07−070
Page 14 of 16

Mounting the switch

1 2 3 4 5
lever

7 6
WK07_070_1109EN 11

No. 0 Designation
1 Switch lever
2 Switching shaft
3 Switching shaft bearing (flanged bearing)
4 Groove
5 Wear sleeve
6 Flattened tooth
7 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 the
switching shaft(2) sits in the notch (7) on the switch lever(1).

" Fit the switch lever(1) on the switching shaft(2), so that the
switch lever(1) sits in the groove (4) on the wear sleeve(5).

768 WK07_070_1109EN
 Maintenancecard
07−070
Page 15 of 16

" Fit the washer to the switching shaft and screw the hexagon
nut onto the switching shaft.

" Lubricate the flanged bearing using the centralized lubrication

system / grease gun.

" Insert the plunger cylinder.

Note
The hydraulic system must be bled once assembly is complete if you
have removed the hydraulic hoses from the plunger cylinders. Do
this by starting up the pump slowly and switching the Stransfer tube
across slowly a few times.

" Adjust the S transfer tube so that it switches correctly.

Maintenance card: Adjusting the S transfer tube

WK07_070_1109EN 769
 Maintenancecard
07−070
Page 16 of 16

770 WK07_070_1109EN
 Maintenancecard
07−071
Page 1 of 14

07–071 Replace the spectacle wear This maintenance card describes how to replace the spectacle wear
plate plate. You will find the maintenance intervals in the maintenance
summary at the start of this chapter.

Note
There are specific risks of an accident associated with maintenance,
inspection and repair work. For this reason, read the chapter "Safety
regulations" 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:

Replacing the transfer tube bearing
Replacing the switching shaft bearing (flanged bearing)
Replacing the thrust ring and wear ring
Adjusting the S transfer tube

You should request the special fitting instructions from us if you have
a spectacle wear plate made from a special material (e.g. hard
metal, hard cast iron, ceramics).

No special tools required.

MA The tightening torques can be found in the corresponding

Spareparts list.

WK07_071_1109EN 771
 Maintenancecard
07−071
Page 2 of 14

Danger of crushing
A pressurized hydraulic system may cause the machine to move
suddenly, which may result in you being seriously injured if you are
working on the machine. To avoid risk, shut the machine down and
secure it against unauthorized or accidental starting.

Caution
Use only suitable lifting equipment for lifting components.

Note
Wear parts must be replaced in the event of one of the following:
 Severe wear is visible
 Concrete is seeping out

772 WK07_071_1109EN
 Maintenancecard
07−071
Page 3 of 14

When maintenance work is carried out, the machine must have been
shut down. The operations necessary for this task are described
below and must be carried out conscientiously. Perform all machine
functions using the remote control.

Shutting down the Proceed as follows to shut down the machine:

machine
" Switch off the engine.

" Dump the pressures completely.

Danger
Dump the accumulator pressure completely in systems with pressure
accumulators.

Starting up the The machine may be started up differently depending on the ma

machine chine model. When you are starting up a truck−mounted concrete
pump, proceed as follows:

" Unlock the EMERGENCY STOP button and sound the horn.

" Switch the engine on.

Caution
Do not switch the pump on until you are called upon to do so.

When you are starting up a stationary concrete pump, proceed as

follows:

" If there is a throttle, set it to one third.

" Start up the engine.

" Select a low output.

" Switch the pump on.

WK07_071_1109EN 773
 Maintenancecard
07−071
Page 4 of 14

Overview
1 2 3 4 5 1

6 6 6
WK07_071_1109EN 1

No. 0 Designation
1 Plunger cylinder
2 Switch lever
3 Clamping bolts with nuts
4 Switching shaft
5 Hexagon nut
6 Fastening bolts for spectacle wear plate

774 WK07_071_1109EN
 Maintenancecard
07−071
Page 5 of 14

Removing the spec- The following describes how to remove the spectacle wear plate.
tacle wear plate
" Shut the machine down.

" Undo the hexagon nut(5) from the switching shaft(4), remove
the plunger cylinder(1) and undo the clamping bolts(3) on the
switch lever(2).
Maintenance card: Replacing the switching shaft bearing
(flanged bearing)

WK07_071_1109EN 2

Pushing the S transfer tube to one side

Note
If there is not enough space available for assembly, you can pull the
pressure connection towards the back.

" Push the S transfer tube away from the spectacle wear plate.

" Undo the eightfastening bolts (6) for the spectacle wear plate.

" Remove the spectacle wear plate from the hopper.

WK07_071_1109EN 775
 Maintenancecard
07−071
Page 6 of 14

Replacing the inter-

mediate rings

1 2 3 4 5

WK07_071_1109EN 3

No. 0 Designation
1 Transition liner
2 Intermediate ring
3 Screw plug
4 Lubrication nipples
5 Grease gun

776 WK07_071_1109EN
 Maintenancecard
07−071
Page 7 of 14

" Using a plastic−faced hammer, strike the old intermediate

ring(2) several times to remove any grout residue that could
block the intermediate ring(2) when it is being removed.

" Replace the screw plug(3) on the underside of the transition

liner(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) is

pressed out.

WK07_071_1109EN 4

Leave the bore open

" Remove the lubrication nipple(4) again.

å This will prevent an air cushion from being formed when the
new intermediate ring(2) is inserted, allowing you to insert the
intermediate ring(2) more easily.

" Clean the surface thoroughly. Remove all concrete and grout
residue.

WK07_071_1109EN 777
 Maintenancecard
07−071
Page 8 of 14

1 2 3
WK07_071_1109EN 5

No. 0 Designation
1 Intermediate ring
2 O−rings
3 Transition liner

" Slide in two O−rings(2) over the mounting surface of the new
intermediate ring(1).

" Grease the mounting surface of the new intermediate ring(1).

" Insert the new intermediate ring(1) into the transition liner(3).

778 WK07_071_1109EN
 Maintenancecard
07−071
Page 9 of 14

" 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).

Fitting the spectacle The following describes how to insert the spectacle wear plate.
wear plate

" Fit the new spectacle wear plate.

WK07_071_1109EN 779
 Maintenancecard
07−071
Page 10 of 14

1 1

2 3

ÉÉÉÉÉÉ
ÉÉÉÉÉÉ
ÉÉÉÉÉÉ
ÉÉÉÉÉÉ
4 5 6 7

WK07_071_1109EN 7

No. 0 Designation
1 Fastening bolts on the left and right
2 Spectacle wear plate
3 Fastening bolts at the top and bottom
4 Intermediate ring
5 O−ring
6 Hopper wall
7 Clearance

780 WK07_071_1109EN
 Maintenancecard
07−071
Page 11 of 14

Caution
The spectacle wear plate(2) only touches the O−rings(5) in the in
termediate rings(4). There is a small gap (7) between the spectacle
wear plate(2) and hopper wall (6). For this reason, only tighten the
fastening bolts(1) on the left and right finger−tight at first, because
otherwise 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 the
new spectacle wear plate(2) finger−tight.

Note
If you have a ceramic spectacle wear plate(2), please contact our
After Sales department to enquire about the tightening torques.

" Using the fastening bolts at the top and bottom (3), screw on
the spectacle wear plate(2) to the appropriate tightening
torque.

Caution
Take 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 the
spectacle wear plate(2) to the appropriate tightening torque.

WK07_071_1109EN 781
 Maintenancecard
07−071
Page 12 of 14

WK07_071_1109EN 8

Close the fitting bore

Caution
The 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 accidentally
lubricate these lubrication nipples as well while lubricating the ma
chine. Over time, this would push out the intermediate rings, and the
spectacle wear plate would be distorted.

" After inserting the new intermediate rings and spectacle wear
plate, seal the pulling bores again using the screw plugs.

782 WK07_071_1109EN
 Maintenancecard
07−071
Page 13 of 14

" 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.

Maintenance card: Replacing the switching shaft bearing
(flanged bearing)

" Adjust the S transfer tube so that it switches correctly.

Maintenance card: Adjusting the S transfer tube

WK07_071_1109EN 783
 Maintenancecard
07−071
Page 14 of 14

784 WK07_071_1109EN
 Maintenancecard
07−072
Page 1 of 8

07–072 Replacing the This maintenance card describes how to replace the S transfer tube.
S transfer tube You will find the maintenance intervals in the maintenance summary
at the start of this chapter.

Note
There are specific risks of an accident associated with maintenance,
inspection and repair work. For this reason, read the chapter "Safety
regulations" 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:

Replacing the transfer tube bearing
Replacing the switching shaft bearing (flanged bearing)
Replacing the S transfer tube wear sleeve
Replacing the thrust ring and wear ring
Adjusting the S transfer tube
Measuring the wall thickness
Measuring the wall thickness of the double−layer pipe

No special tools required.

MA The tightening torques can be found in the corresponding

Spareparts list.

WK07_072_1109EN 785
 Maintenancecard
07−072
Page 2 of 8

Danger of crushing
A pressurized hydraulic system may cause the machine to move
suddenly, which may result in you being seriously injured if you are
working on the machine. To avoid risk, shut the machine down and
secure it against unauthorized or accidental starting.

Caution
Use only suitable lifting equipment for lifting components.

Note
Wear parts must be replaced in the event of one of the following:
 Severe wear is visible
 Concrete is seeping out

We recommend that the switch lever also be replaced when the S

transfer tube is replaced. Practical experience has shown that the
toothing 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.

Maintenance card: Replacing the switching shaft bearing

(flanged bearing)

786 WK07_072_1109EN
 Maintenancecard
07−072
Page 3 of 8

When maintenance work is carried out, the machine must have been
shut down. The operations necessary for this task are described
below and must be carried out conscientiously. Perform all machine
functions using the remote control.

Shutting down the Proceed as follows to shut down the machine:

machine
" Switch off the engine.

" Dump the pressures completely.

Danger
Dump the accumulator pressure completely in systems with pressure
accumulators.

Starting up the The machine may be started up differently depending on the ma

machine chine model. When you are starting up a truck−mounted concrete
pump, proceed as follows:

" Unlock the EMERGENCY STOP button and sound the horn.

" Switch the engine on.

Caution
Do not switch the pump on until you are called upon to do so.

When you are starting up a stationary concrete pump, proceed as

follows:

" If there is a throttle, set it to one third.

" Start up the engine.

" Select a low output.

" Switch the pump on.

WK07_072_1109EN 787
 Maintenancecard
07−072
Page 4 of 8

S transfer tube vari-

ants

1 2

WK07_072_1109EN 1

No. 0 Designation
1 S transfer tube with bolted switching shaft
2 S transfer tube with welded switching shaft

Note
Whichever variant of S transfer tube is fitted, the recommended pro
cedure for dismantling is as described below. The S transfer tube
with bolted switching shaft may also be dismantled and reassembled
in the hopper. The tube is then dismantled as described in the
S
transfer tube with bolted switching shaft" maintenance card.

You should also consult the
Divided hopper" maintenance card if

your machine has a divided hopper.

788 WK07_072_1109EN
 Maintenancecard
07−072
Page 5 of 8

Removing the S Replace the S transfer tube if the wall thickness has fallen below the
transfer tube minimum.

Maintenance card: Measuring the wall thickness

Maintenance card: Measuring the wall thickness of the double−

layer pipe

" Shut the machine down.

" Attach suitable lifting gear to the S transfer tube.

" Remove the transfer tube bearing.

Maintenance card: Replacing the transfer tube bearing

" Remove the switching shaft bearing (flanged bearing).

Maintenance card: Replacing the switching shaft bearing
(flanged bearing)

WK07_072_1109EN 2

Removing the mixer shaft

" Remove the mixer shaft.

WK07_072_1109EN 789
 Maintenancecard
07−072
Page 6 of 8

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 outlet
is free.

" Lift the S transfer tube outlet opening first upwards and out.

Note
If just the wear sleeve is heavily worn, you can also replace just the
wear 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 reverse
order to removal.

790 WK07_072_1109EN
 Maintenancecard
07−072
Page 7 of 8

" 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).

Maintenance card: Replacing the switching shaft bearing
(flanged bearing)

" Fit the transfer tube bearing.

Maintenance card: Replacing the transfer tube bearing

" Adjust the S transfer tube so that it switches correctly.

Maintenance card: Adjusting the S transfer tube

WK07_072_1109EN 791
 Maintenancecard
07−072
Page 8 of 8

792 WK07_072_1109EN
 Maintenancecard
07−073
Page 1 of 8

07–073 Replacing the This maintenance card describes how to replace the wear sleeve on
S transfer tube wear sleeve the S transfer tube. You will find the maintenance intervals in the
maintenance summary at the start of this chapter.

Note
There are specific risks of an accident associated with maintenance,
inspection and repair work. For this reason, read the chapter "Safety
regulations" 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:

Replacing the transfer tube bearing
Replacing the switching shaft bearing (flanged bearing)

No special tools required.

MA The tightening torques can be found in the corresponding

Spareparts list.

WK07_073_1109EN 793
 Maintenancecard
07−073
Page 2 of 8

Danger of crushing
A pressurized hydraulic system may cause the machine to move
suddenly, which may result in you being seriously injured if you are
working on the machine. To avoid risk, shut the machine down and
secure it against unauthorized or accidental starting.

Caution
Use only suitable lifting equipment for lifting components.

Note
Wear parts must be replaced in the event of one of the following:
 Severe wear is visible
 Concrete is seeping out

794 WK07_073_1109EN
 Maintenancecard
07−073
Page 3 of 8

When maintenance work is carried out, the machine must have been
shut down. The operations necessary for this task are described
below and must be carried out conscientiously. Perform all machine
functions using the remote control.

Shutting down the Proceed as follows to shut down the machine:

machine
" Switch off the engine.

" Dump the pressures completely.

Danger
Dump the accumulator pressure completely in systems with pressure
accumulators.

Starting up the The machine may be started up differently depending on the ma

machine chine model. When you are starting up a truck−mounted concrete
pump, proceed as follows:

" Unlock the EMERGENCY STOP button and sound the horn.

" Switch the engine on.

Caution
Do not switch the pump on until you are called upon to do so.

When you are starting up a stationary concrete pump, proceed as

follows:

" If there is a throttle, set it to one third.

" Start up the engine.

" Select a low output.

" Switch the pump on.

WK07_073_1109EN 795
 Maintenancecard
07−073
Page 4 of 8

Removing the wear If just the wear sleeve is heavily worn, you can replace it without hav

sleeve ing to replace the S transfer tube. You do not have to remove the S
transfer tube to do this.

" Shut the machine down.

" Remove the transfer tube bearing.

Maintenance card: Replacing the transfer tube bearing

" Loosen the hexagon nut on the switching shaft and the clamp

ing bolts on the switch lever.
Maintenance card: Replacing the switching shaft bearing
(flanged bearing)

Danger
There is a risk of burning during heating and fitting of the new wear
sleeve. Use suitable protective equipment.

796 WK07_073_1109EN
 Maintenancecard
07−073
Page 5 of 8

1 2 3
WK07_073_1109EN 1

No. 0 Designation
1 Welds
2 Tube outlet
3 Wear sleeve

Removal when the S If the S transfer tube has been fitted, proceed as follows:
transfer tube is fitted
" Weld a metal pin onto the wear sleeve.

Caution
When cutting open the welds, take care not to damage the S transfer
tube.

" Carefully cut open the welds (1) on the front face between the
S transfer tube outlet(2) and wear sleeve(3) using an angle
grinder.

" Heat up the wear sleeve(3) evenly to approx. 140°C.

WK07_073_1109EN 797
 Maintenancecard
07−073
Page 6 of 8

" Using a hammer, strike the metal pin to release the wear
sleeve.

" Remove the wear sleeve(3).

Removal when the S If the S transfer tube has been removed, proceed as follows:
transfer tube has been
removed Caution
When 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 the
S transfer tube outlet(2) and wear sleeve(3) using an angle
grinder.

" 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).

798 WK07_073_1109EN
 Maintenancecard
07−073
Page 7 of 8

Fitting a wear sleeve

1 2
WK07_073_1109EN 2

No. 0 Designation
1 Wear sleeve
2 Tube outlet

Note
The wear sleeve(1) is chrome−plated, and must not therefore be
heated 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) and
allow the wear sleeve(1) to cool.

" On the front face, evenly position four welds between the wear
sleeve(1) and tube outlet(2).

" Grind the four welds.

WK07_073_1109EN 799
 Maintenancecard
07−073
Page 8 of 8

" Fit the transfer tube bearing.

Maintenance card: Replacing the transfer tube bearing

" Tighten the hexagon nut on the switching shaft and the clamp

ing bolts on the switch lever.
Maintenance card: Replacing the switching shaft bearing
(flanged bearing)

7100 WK07_073_1109EN
 Maintenancecard
07−074
Page 1 of 6

07–074 Replacing the thrust ring This maintenance card describes how to replace the thrust ring and
and wear ring wear ring on the S transfer tube. You will find the maintenance inter

vals in the maintenance summary at the start of this chapter.

Note
There are specific risks of an accident associated with maintenance,
inspection and repair work. For this reason, read the chapter "Safety
regulations" 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:

Replacing the transfer tube bearing
Replacing the switching shaft bearing (flanged bearing)
Replacing the spectacle wear plate
Adjusting the S transfer tube

No special tools required.

MA The tightening torques can be found in the corresponding

Spareparts list.

WK07_074_1109EN 7101
 Maintenancecard
07−074
Page 2 of 6

Danger of crushing
A pressurized hydraulic system may cause the machine to move
suddenly, which may result in you being seriously injured if you are
working on the machine. To avoid risk, shut the machine down and
secure it against unauthorized or accidental starting.

Caution
Use only suitable lifting equipment for lifting components.

Note
Wear parts must be replaced in the event of one of the following:
 Severe wear is visible
 Concrete is seeping out

7102 WK07_074_1109EN
 Maintenancecard
07−074
Page 3 of 6

When maintenance work is carried out, the machine must have been
shut down. The operations necessary for this task are described
below and must be carried out conscientiously. Perform all machine
functions using the remote control.

Shutting down the Proceed as follows to shut down the machine:

machine
" Switch off the engine.

" Dump the pressures completely.

Danger
Dump the accumulator pressure completely in systems with pressure
accumulators.

Starting up the The machine may be started up differently depending on the ma

machine chine model. When you are starting up a truck−mounted concrete
pump, proceed as follows:

" Unlock the EMERGENCY STOP button and sound the horn.

" Switch the engine on.

Caution
Do not switch the pump on until you are called upon to do so.

When you are starting up a stationary concrete pump, proceed as

follows:

" If there is a throttle, set it to one third.

" Start up the engine.

" Select a low output.

" Switch the pump on.

WK07_074_1109EN 7103
 Maintenancecard
07−074
Page 4 of 6

Removing the thrust To remove the thrust ring and wear ring, proceed as follows:
ring and wear ring
" Shut the machine down.

" Remove the transfer tube bearing.

Maintenance card: Replacing the transfer tube bearing

" Loosen the hexagon nut on the switching shaft and the clamp

ing bolts on the switch lever.
Maintenance card: Replacing the switching shaft bearing
(flanged bearing)

" Inspect the spectacle wear plate and replace it if required.

Maintenance card: Replacing the spectacle wear plate

7104 WK07_074_1109EN
 Maintenancecard
07−074
Page 5 of 6

1 2
WK07_074_1109EN 1

No. 0 Designation
1 Thrust ring
2 Wear ring

" Remove the old wear ring (2) and the old thrust ring (1).

Fitting the thrust ring To fit the thrust ring and wear ring, proceed as follows:
and wear ring
" 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 S
transfer tube.

" Fit the transfer tube bearing.

Maintenance card: Replacing the transfer tube bearing

" Adjust the S transfer tube so that it switches correctly.

Maintenance card: Adjusting the S transfer tube

WK07_074_1109EN 7105
 Maintenancecard
07−074
Page 6 of 6

7106 WK07_074_1109EN
 Maintenancecard
07−075
Page 1 of 14

07–075 Adjusting the This maintenance card describes how to adjust the S transfer tube.
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.

Note
There are specific risks of an accident associated with maintenance,
inspection and repair work. For this reason, read the chapter "Safety
regulations" 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:

Replacing the switching shaft bearing (flanged bearing)

No special tools required.

MA The tightening torques can be found in the corresponding

Spareparts list.

WK07_075_1109EN 7107
 Maintenancecard
07−075
Page 2 of 14

Danger of crushing
A pressurized hydraulic system may cause the machine to move
suddenly, which may result in you being seriously injured if you are
working on the machine. To avoid risk, shut the machine down and
secure it against unauthorized or accidental starting.

Caution
Use only suitable lifting equipment for lifting components.

Note
Wear parts must be replaced in the event of one of the following:
 Severe wear is visible
 Concrete is seeping out

7108 WK07_075_1109EN
 Maintenancecard
07−075
Page 3 of 14

You will have to shut down and restart the machine a number of
times. The operations necessary for this task are described below
and must be carried out conscientiously. Perform all machine func

tions using the remote control.

Shutting down the Proceed as follows to shut down the machine:

machine
" Switch off the engine.

" Dump the pressures completely.

Danger
Dump the accumulator pressure completely in systems with pressure
accumulators.

Starting up the The machine may be started up differently depending on the ma

machine chine model. When you are starting up a truck−mounted concrete
pump, proceed as follows:

" Unlock the EMERGENCY STOP button and sound the horn.

" Switch the engine on.

Caution
Do not switch the pump on until you are called upon to do so.

When you are starting up a stationary concrete pump, proceed as

follows:

" If there is a throttle, set it to one third.

" Start up the engine.

" Select a low output.

" Switch the pump on.

WK07_075_1109EN 7109
 Maintenancecard
07−075
Page 4 of 14

Prestressing the S First, prestress the S transfer tube.

transfer tube
" Shut the machine down.

5 6 7 8

1 2 3 4
WK07_075_1109EN 1

No. 0 Designation
1 Spectacle wear plate
2 Wear ring
3 S transfer tube
4 Thrust ring
5 Gap
6 Hexagon nut
7 Retaining plate
8 Switch lever
9 Clamping bolts

Note
Make sure that the thrust ring (4) is not damaged when it is pressed
in.

" Unscrew the clamping bolts(9) from the switch lever(8).

7110 WK07_075_1109EN
 Maintenancecard
07−075
Page 5 of 14

" Tighten the hexagon nut(6) on the switching shaft so that the
wear ring(2) lies flat against the spectacle wear plate(1).

Note
A gap (5) must be maintained between the S transfer tube(3) and
wear ring(2) so that the S transfer tube(3) switches correctly.

" Check that the wear ring (2) makes contact with the spectacle
wear plate (1) on all sides.

" Slowly tighten the hexagon nut(6) by half a turn.

å The thrust ring (4) is then compressed by 1.5mm.
å The gap (5) between the S transfer tube(3) and wear
ring(2) is set.

" Ensure that one surface on the hexagon nut(6) is horizontal at

the top so that the retaining plate(7) can be refitted.

" Fit the retaining plate(7).

Note
Use only new nuts for the clamping bolts (9).

" Insert the clamping bolts (9) into the switch lever (8) and fit
new nuts.

" Tighten the clamping bolts(9) to the required torque.

" Further assembly is carried out in the reverse sequence to dis

assembly.
Maintenance card: Replacing the switching shaft bearing
(flanged bearing)

" Check that all covers and other safety equipment have been
refitted and are fully functional.

WK07_075_1109EN 7111
 Maintenancecard
07−075
Page 6 of 14

Setting the switching The switching overlap is set to the optimum if the wear ring is central
overlap to 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 S
transfer tube must not be either too great or too small.

Spectacle wear plate

with wear ring
1 2

WK07_075_1109EN 2

No. 0 Designation
1 Swing angle too great
2 Swing angle too small
3 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 cylinder
with a thicker or thinner one as required. The right−hand switching
overlap is corrected on the left in the same way.

7112 WK07_075_1109EN
 Maintenancecard
07−075
Page 7 of 14

1 2 3

WK07_075_1109EN 3

No. 0 Designation
1 Plunger cylinder
2 Ball cup
3 Packing washer

" Start the machine up.

WK07_075_1109EN 4

Plunger cylinder extended

" Allow one plunger cylinder to retract completely.

" Shut the machine down.

WK07_075_1109EN 7113
 Maintenancecard
07−075
Page 8 of 14

WK07_075_1109EN 5

No. 0 Designation
1 Marking the spectacle wear plate

" Use a felt tip pen or oil chalk to mark the position of the wear
ring on the spectacle wear plate.

" Start the machine up.

" Allow the other plunger cylinder to retract.

" Shut the machine down.

" Determine to which side and by how many millimetres the

circle you have drawn is offset against the circle of the spec

tacle wear plate.

7114 WK07_075_1109EN
 Maintenancecard
07−075
Page 9 of 14

Spectacle wear plate

with sample markings

1 2

WK07_075_1109EN 6

No. 0 Designation
1 Packing washer too thin
2 Packing washer too thick
3 Optimum packing washer

To decrease the swing angle of the Stransfer tube by 4mm, the

fitted packing washer must be replaced by one which is 2mm
thicker.
To increase the swing angle of the Stransfer tube by 4mm, the fitted
packing washer must be replaced by one which is 2mm thinner.

WK07_075_1109EN 7115
 Maintenancecard
07−075
Page 10 of 14

1 2

WK07_075_1109EN 7

No. 0 Designation
1 Plunger cylinder
2 Locking plate

" Remove the locking plate(2) of the extended plunger cylin

der(1).

10300800

Removing the plunger cylinders

Note
The plunger cylinders can be pushed back as illustrated. It is, how
ever, also possible to screw a bolt into the jacking bores for the ball
cups and to push the plunger cylinders out with the ball cups.

7116 WK07_075_1109EN
 Maintenancecard
07−075
Page 11 of 14

" Force the piston of the extended plunger cylinder back a little
and remove the plunger cylinder with the hydraulic hoses.

1 2

WK07_075_1109EN 8

No. 0 Designation
1 Ball cup
2 Packing washer

" Remove the hexagon ball cup (1) along with the packing
washer (2).

Caution
No 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 the
ball cup (1).

" Fit the plunger cylinder and locking plate.

" Start the machine up.

WK07_075_1109EN 7117
 Maintenancecard
07−075
Page 12 of 14

" Allow the Stransfer tube to switch over a few times. Stoppen
Sie, wenn die S−Rohrweiche auf der noch nicht markierten Bril

lenplattenseite steht.

" Shut the machine down.

" Check the switching overlap of the other side of the spectacle
wear plate and correct accordingly.

Switching overlap on The two plunger cylinders must extend to the same extent on ma

VHS control chines with fully hydraulic control (VHS) and active signal tapping in
the plunger cylinders.

20300703

Plunger cylinder extended

" First set a switching overlap of the wear ring and the spectacle
wear plate.

" Allow the plunger cylinder (1) to extend to its end position.

" Shut the machine down.

" Measure how far the plunger cylinder has extended. (Measure

ment E1)

" Start the machine up.

7118 WK07_075_1109EN
 Maintenancecard
07−075
Page 13 of 14

" Allow the plunger cylinder (2) to extend to its end position.

" Shut the machine down.

" 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 have

to change the packing washers as described below if the two
measurements are not equal:

" Swap the packing washer on the plunger cylinder with the
greater measurement for a washer (E1−E2):2 thinner.

" Swap the packing washer on the plunger cylinder with the
smaller measurement for a washer (E1−E2):2 thicker.

Note
This setting must be checked after a running−in period of approxi
mately 100 operating hours.

WK07_075_1109EN 7119
 Maintenancecard
07−075
Page 14 of 14

7120 WK07_075_1109EN
 Maintenancecard
07−078
Seite 1 von 2

07–078 Resolver on the switching This maintenance card describes how to fit the resolver on the
shaft switching shaft.

Note
There are specific risks of accidents associated with maintenance,
inspection and repair work. For this reason, read the chapter

Safetyregulations" and the description of the
Residualrisks during
maintenance, inspection and repair work" at the start of the chapter
entitled
Maintenance" (i.e.this chapter).

No further maintenance cards required.

No special tools required.

Note
The resolver measures the position of the S transfer tube and con
trols the graphic display of the switchover procedure in the Ergonic
Graphic Display (EGD).

If you want to carry out service and maintenance work on the S

transfer tube, you must remove the resolver from the switching shaft
and refit it as described in the following.

WK07_078_1304EN 7121
 Maintenancecard
07−078
Seite 2 von 2

5 4 3

WK07_078_1304EN 1

No. 0 Designation
1 Connecting cable
2 Resolver
3 Magnetic sensor
4 Switch lever
5 Switch cylinders

" Fit the resolver(2) as shown in the graphic.

å The resolver is located in its electrical middle position.

" Maintain the reacting distance a" (a = 8 +/− 4mm).

7122 WK07_078_1304EN
 Wartungskarte
08−007
Page 1 of 2

08–007 Lubrication This maintenance card describes how to lubricate the machine. The
machine 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.

Hinweis
There 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 maintenance, inspection
and repair work" at the start of the chapter entitled "Maintenance"
(i.e. this chapter).

No further maintenance cards required.

The following special tools are required:

Grease gun

Hinweis
Use only those lubricants listed in the lubricant recommendation
table.

WK08_007_1109EN 7123
 Wartungskarte
08−007
Page 2 of 2

1 2

WK08_007_1109EN 1

1 Plate indicating the lubrication intervals

2 Centralized lubrication nipple strip
3 Lubrication nipple for the lower bearings on the switch cylinder

" Lubricate each lubrication nipple with a grease gun until clean
grease exits from the lubrication point.

Hinweis
The lubrication interval is specified for normal operation. More fre
quent lubrication may be necessary under extreme conditions.

7124 WK08_007_1109EN
 Maintenancecard
10−007
Page 1 of 6

10–007 Measuring the wall thick- This maintenance card describes how to measure the wall thickness
ness (Machines with of delivery lines. You will find the maintenance intervals in the main

S transfer tube) tenance summary at the start of this chapter.

Note
There are specific risks of an accident associated with maintenance,
inspection and repair work. For this reason, read the chapter "Safety
regulations" 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).

No further maintenance cards required.

The following special tools are required:

Wall thickness measuring device

MA The tightening torques can be found in the corresponding

Spareparts list.

WK10_007_1109EN 7125
 Maintenancecard
10−007
Page 2 of 6

Note
Delivery lines are subject to constant wear. Measurement of the wall
thickness is particularly important before starting on large jobs.
You will obtain reliable results for your measurements if you carry out
the test with the measuring device recommended by Putzmeister.

Danger of explosion
The delivery line can burst once it reaches a high delivery pressure if
the wall thickness of the delivery line has decreased below the mini
mum required, particularly if a blockage has built up.

7126 WK10_007_1109EN
 Maintenancecard
10−007
Page 3 of 6

Caution
Only tap the delivery line with a piece of hardwood (hammer handle).
Otherwise, dents may be created and these will lead to more rapid
wear. In addition, the hardened lining of high wear resisting pipes
may flake off the inside of the pipe. The pipe can burst at points that
have suffered heavy wear.

11000101

Tapping the delivery line with a hammer handle

Straight pipes 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 graph
below.

Bends Uniform wear can be achieved by regularly rotating the bends

through 180°. The wear on the external radius of a bend is greater
than that on the internal radius or on straight pipes. You should,
therefore, take special care when measuring the wall thickness of the
external radius of a bend.
The minimum wall thickness for bends is shown in the graph below.

11000200

Rotate delivery pipes and bends regularly

WK10_007_1109EN 7127
 Maintenancecard
10−007
Page 4 of 6

S transfer tube The minimum wall thickness for the S transfer tube depends on the
maximum possible operating pressure. Furthermore, the fact that the
S transfer tube is subject to greater stress at the point at which the
torque is applied (switching shaft − S transfer tube) must be taken
into consideration.

WK10_007_1109EN 1

X = Area of heavy loading

Operating pressure up to Guide value for wall thick-

130 bar ness

AreaA 8−10mm
AreaB 6−8mm

Note
We should draw your attention to the fact that the S transfer tube is
subject to varying loading as a result of the dynamic loading during
pumping. There is no general method for calculating the minimum
wall 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 the
maximum pressure in the event of a blockage, and in this case the
wall thickness may no longer be adequate.

If the operating pressure is higher than 130bar, you must ask

Putzmeister what the minimum wall thickness is.

7128 WK10_007_1109EN
 Maintenancecard
10−007
Page 5 of 6

Measuring Follow the Operating Instructions supplied with the measuring de

vice when carrying out measurements. Do not measure the wall
thickness of the delivery line at just one point, but around the entire
circumference of the delivery pipes.
The minimum wall thickness is shown in the graph below.

Caution
Pipes and bends must be replaced as soon as the wall thickness
has declined to the value for the minimum wall thickness.
Putzmeister accepts no liability if the wall thickness is less than the
minimum wall thickness.

Note
As 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 delivery
line is subject to varying loading as a result of the dynamic loading
during pumping. There is no general method for calculating the mini
mum wall thickness for this loading, which depends on the individual
circumstances, 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 of

blockages, meaning that the wall thickness will no longer be ad
equate and the delivery line will burst.

WK10_007_1109EN 7129
 Maintenancecard
10−007
Page 6 of 6

Graph Minimum wall thickness as a function of operating pressure

1 High pressure
2 Maximum delivery pressure

7130 WK10_007_1109EN
 Maintenancecard
10−044
Page 1 of 2

10–044 Measuring the wall thick- This maintenance card describes how to measure the wall thickness
ness of two–layer pipes of two−layer delivery lines.

Note
There 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 maintenance, inspection
and repair work" at the start of the chapter entitled "Maintenance"
(i.e. this chapter).

See also the maintenance cards:

Measuring the wall thickness

The following special tools are required:

Wall thickness measuring device, material no. 454460

Note
Observe all safety instructions in the machine−specific Operating
Instructions and in the Safety manual.

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

WK10_044_1109EN 7131
 Maintenancecard
10−044
Page 2 of 2

Inspecting two–layer Inspect two−layer delivery pipes and delivery line elbows
delivery pipes and (DN125,max. concrete pressure 85 bar) as follows:
delivery line elbows
" Visual inspection for cracks. Replace in case of crack
formation.

" Measure the wall thickness at the measuring points P1 and P 2.

Replace if the wall thickness has fallen below the minimum
required (see table).

Type Minimum (mm)

No. DN 125
P1 P2
up to 85 bar
Twin Pipe Twin Cast
1.1 7.1 + 3.6 4.1 3.6
Delivery line elbow
1.2 7.0 + 2.0 7.0 3.0
2.1 2.5 + 2.0 2.5 3.3
2.2 2.5 + 2.0 2.5 4.9
Delivery pipe
2.3 5.6 + 3.0 3.7 3.7
2.4 5.6 + 3.0 3.7 3.1

1.1 – 1.2
Delivery line elbow
Measuring points
P1/P2
Minimum (seetable)

2.1 – 2.4
Delivery pipe
Measuring points
P1/P2
Minimum (seetable)

Extract from Esser Service Manual – EM 070190, see Technical Appendix

7132 WK10_044_1109EN
 8 Index of key words

In this section you will find the most important key words with the
number of the page on which you will find the key word as a heading
in the left margin. This Index of key words is listed alphabetically by
the main concepts. These are subdivided into associated sub−con

cepts, marked with a dash.

BP11_001_0201EN
 Indexofkeywords

Chassis Control devices

A
Crawler track, 5
7
Drive cylinder emergency operation,
Abbreviations, G
15
Description of the functions, 3
10 3
76, 6
17

F 8, 5
4
Electrical, 3
20
Accessories and attachments, 2
14

F25, 5
4
Emergency operation − transfer tube,
After Sales Service personnel, Defini-
F80, 5
5 3
76, 6
17
tion of terms, 2
3
Hydraulic, 3
74

Static base structure, 3
11, 5
7
Agitator, 4
18
Transport, 5
4
Hydraulic fluid radiator, 3
79

Function description, 3
14
Magnetic switches distributor casing,
Checks
Agitator gearbox, Transmission oil, 3
69

Function checks, 4
9
7
17
Pump control system, 3
76, 6
17

Visual checks, 4
1
Agitator hopper, Filling, 6
7 Cooling, 6
15
Cleaning, 2
46, 6
19
Agitator safety cutout, 3
67
Catch basket, 6
23 Copyright, 1
2

Acknowledge, 4
14
Cleaning agents, 2
47 Corner bearing load, 2
29

Inspection, 4
12
Compressed air, 2
48 Crawler track, 3
11, 5
7

Unexpected restart, 4
14
Compressed air cleaning, 6
21
Approach route
Concrete leavings, 6
20

For the machine, 5
11
Delivery line, 6
28 D

For truck mixers, 5
11
High−pressure water cleaning, 6
32
Danger zone, 2
4, 2
7

Minimum clearance from pits, 5
13
Hopper, delivery cylinder and S trans

fer tube, 6
35
Delivery line systems, 2
8
Arm assembly, Definition of terms,
Guiding the end hose, 2
8, 2
37

Mark the water hose, 6
27
2
1
Hopper, 2
8

Post−cleaning procedure, 2
49, 6
41
Assembly, Stationary delivery line,
Preparations, 6
22
Machine, 2
8
5
19
Sponge ball, 6
22
Placing boom, 2
7
Authorized inspector, Definition of
Suction cleaning, 6
30
Stationary delivery line, 5
20
terms, 2
3
T−delivery pipe with wash−out port,
Support legs and support feet, 2
7
Auxiliary personnel, Definition of 6
25 Definition of terms
terms, 2
2
Wash−out adaptors, 6
24
After Sales Service personnel, 2
3

With auxiliary pump, 6
33
Arm assembly, 2
1
Cleaning agents, 2
47
Authorized inspector, 2
3
B Clearances

Auxiliary personnel, 2
2

Base structure, 2
1
Base structure, Definition of terms,
From high−voltage lines, 2
21
2
1
Boom pedestal, 2
1

To delivery lines, 2
42

Concrete pump, 2
1
Blockages, 2
41, 6
12 Cold weather, 2
39
Danger zone, 2
4, 2
7
Boom pedestal, Definition of terms, Components
Delivery line systems, 2
2
2
1
Electrical components, 2
56
Guiding the end hose, 2
2
Breaks in pumping, 6
13
Other, 3
78
Hoseman, 2
2

Overview, 3
1
Machine, 2
1

Safety
relevant components, 2
53
Machine operator, 2
2
C Compressed air cleaning, 2
48, 6
21
Maintenance, 2
3
Cable remote control, 3
63
Manufacturer, 2
2
Concrete leavings, 6
20

Operator, 2
2
Catch basket, 6
23 Concrete properties, 6
6
Place of work, 2
4, 2
6
Centralized lubrication system Concrete pump, Definition of terms,
Placing boom, 2
1

Description of the functions, 3
18 2
1
Qualified personnel, 2
3

Grease, 7
18 Condensate water, 4
3
Signaller, 2
2

Low temperature grease, 7
18
Subject expert, 2
3
Control cabinet with SPC display unit,
Change-over, Description of the func- 3
21, 3
27
Truck mixer, 2
2
tions, 3
13
Truck mixer driver, 2
3

Working area, 2
4, 2
6

i
 Indexofkeywords

Delivery line Electromagnetic compatibility, 3
6
Vibrator, 4
19

Cleaning, 6
28 Electrostatic charging, 2
24 Function description, Agitator, 3
14

Measuring the wall thickness, 7
131
EMC, 3
6 Functional fluids, 2
59, 7
12

Measuring the wall thickness (Machi

nes with S transfer tube), 7
125 Emergency operation, 3
62 Fuse box, 3
62

Drive cylinder, 3
76, 6
17
Delivery line systems, 2
40

Transfer tube, 3
76, 6
17

Clearance to delivery lines, 2
42

Continuation delivery lines, 2
43 EMERGENCY STOP button, 2
36,
G

Danger zone, 2
8 3
63, 3
65, 4
11 General conditions

Definition of terms, 2
2 EMERGENCY STOP function, 4
11
For using a concrete pump, 3
15

Fastening delivery lines, 2
42 EOC, Ergonic Output Control, 3
59
Height of job, 3
16

Opening the delivery line, 2
42
Operating temperature, 3
17
Ergonic Graphic Display, Menu struc-

Securing delivery lines, 2
40
Service life, 3
15
ture, 3
29

Shutting−off, diverting, cleaning, 2
43
Site of use, 3
16
Ergonic Output Control, 3
59

Suitable delivery line, 2
40 Guiding the end hose, 2
37

Tightness and blockages, 2
41 Exhaust fumes, 2
59
Danger zone, 2
8, 2
37
Delivery piston, Piston replacement, Extensions, End hose and placing
Definition of terms, 2
2
7
43 boom, 2
12
Ergonomically, 2
38
Description of the functions, 3
10
Extending, 2
12

Impermissible end hose, 2
12

Centralized lubrication system, 3
18

Change
over, 3
13
F
F 8 chassis, 5
4

Chassis, 3
10

Pump, 3
12
H
F 25 chassis, 5
4

Pumping, 3
13 Hand signals
F 80 chassis, 5
5

Reverse pumping, 3
13
Driving, 5
5, 5
8

S transfer tube, 3
13 Face mask, 2
19
Pumping operations, 6
3

Support legs, 3
11 Fastening, Stationary delivery line, Hearing protectors, 2
18

Water box, 3
13 5
23
Height of job, 3
16
Designated use, 2
9 Filling with fuel, Machine, 6
5
High–pressure delivery, 2
14

Inspection intervals, 2
10 Filter

Retesting (safety inspection), 2
9
Pressure filter, 4
17 High–pressure water cleaning, 6
32
Diesel engine, 6
14
Suction filter, 4
16 High–voltage lines, 2
21

Switching on, 4
7 Filter change, Pressure filter, 7
37
Clearances, 2
21

High−voltage warning device, 2
23
Discharge voltage pattern, 2
21 Filter condition, 4
16

Procedure in the event of a flash over,
Disposal, Machine, 2
60
Pressure filter, 3
77 2
23
Downpipe, 5
26
Suction filter, 3
77
High–voltage warning device, 2
23
Drills , Connect , 2
38 Flanged bearing, Replacing, 7
55
Hopper
Driving, 2
32 Flared screwed joint, 7
11
Cleaning, 6
35

Before moving off, 5
6 Flash over, 2
23
Danger zone, 2
8

During the journey, 5
7 Fluid drain cock, 7
27 Hoseman, Definition of terms, 2
2

Hand signals, 5
5, 5
8
Fumes Hydraulic fluid

Exhaust, 2
59
Fluid drain cock, 7
27
E
Noise, 2
58
Full fluid change, 7
27
Function checks, 4
9, 7
25
Radiator, 3
79
Earthing, 2
24
Agitator, 4
18 Hydraulic fluid radiator, 3
79, 4
3
EGD symbols, Agitator safety cutout,
Agitator safety cutout, 4
12 Hydraulic hoses, 2
58
3
39
EMERGENCY STOP function, 4
11
Maintenance, 7
31
Electrical components, 2
56
Filter condition, 4
16
Hydraulic system, 4
1
Electrical power, 2
55
Magnetic switches, 4
9

Pump, 4
9 Hydraulic systems, 2
57

Power at the construction site, 2
56

ii
 Indexofkeywords

Setting up, 5
14

I
Switching off, 4
20
N
Icons, 1
3
Switching on, 4
7 Noise emissions, 2
58
Impermissible end hose, 2
12 Machine operator

Definition of terms, 2
2
Impermissible working area, 2
6,
2
13
Responsibility of the machine operator, O
2
15 Operating Instructions, 2
16
Inputs and outputs menu, Symbols in
the menu bar, 3
57 Magnetic switches, 3
69 Operating procedures, 2
16, 2
17

Connector with LEDs, 3
72
Inspection intervals, 2
10 Operating temperature, 3
17

Function check, 4
9
Instructions for laying the line, Statio- Operator, Definition of terms, 2
2
Magnetic switches distributor casing,
nary delivery line, 5
21 Output controller, 3
75
3
69
Intermediate rings on the transition Overheating, 6
14
Maintenance, Definition of terms, 2
3
liner, Replacing, 7
76
Maintenance and special work, 2
50 Overview, Components, 3
1
Maintenance cards
L
Adjusting the S transfer tube, 7
107
P
Liability, Exclusion, 2
14
Changing the hydraulic fluid, 7
27

Changing the pressure filter element, Parts in contact with concrete, 4
5
Lifting eyes, 5
2, 5
3 7
37 Personal protective equipment, 2
18
Lifting loads, 2
11, 2
26
Delivery piston replacement, 7
43
Personnel, 2
14
Lifting points, 2
34
Function checks, 7
25

Qualifications, 2
15

Hydraulic hoses, 7
31
Loading, 2
26, 2
34, 5
1
Requirements, 2
15

Lubrication, 7
123

Lifting points, 2
34
Responsibility of the machine operator,

Measuring the wall thickness, 7
131
Locking, 3
26
Measuring the wall thickness (Machi

2
15
Lubricant analysis, 7
12, 7
14 nes with S transfer tube), 7
125 Place of work, 2
4, 2
6

Replace the spectacle wear plate,
Place of work − hoseman, 2
6
Lubricant recommendation
7
71
Place of work − machine operator, 2
6

Agitator gearbox, 7
17

Replacing the S transfer tube, 7
85
Place of work − truck mixer driver, 2
6

Engine oil, 7
17

Replacing the S transfer tube wear
Pumping operations, 2
44

General, 7
15
sleeve, 7
93 Placing boom, 2
35, 2
39

Greases, 7
18

Replacing the switching shaft bearing
Climbing, 2
13

Hydraulic fluids, 7
19
(flanged bearing), 7
55
Danger zone, 2
7

Low temperature grease, 7
18

Replacing the thrust ring and wear
Definition of terms, 2
1

Oils, 7
17
ring, 7
101

Pump tube grease, 7
18
Extending, 2
12

Replacing the transfer tube bearing,

Rotor gearbox, 7
17
Procedure in storms, 2
39
7
49

Slewing gear transmission, 7
17
Unfolding, 2
35

Resolver on the switching shaft, 7
121

Transfer gearbox, 7
17
Wind speeds, 2
39

Vacuum meter, 7
35

Transmission oil, 7
17
Working on the placing boom, 2
53

Visual checks, 7
23
Lubrication, Grease, 7
18 Power, 2
56
Manufacturer, Definition of terms, 2
2
Lubrication menu, Symbols in the Power at the construction site, 2
56
Measuring the wall thickness, 7
131
menu bar, 3
54 Preparations for cleaning, 6
22

Machines with S transfer tube, 7
125
Lubrication points, 4
3 Pressure filter, 3
77
Minimum clearance from pits, 5
13
Mobile machines, 2
27 Pressure gauge, 3
77
M
Set−up site, 2
27 Profiled ring joint, 7
11

Supporting ground, 2
28 Protective equipment, 2
18, 2
54
Machine
Monitoring, 6
10
Face mask and respiratory protector,

Danger zone, 2
8
2
19

Definition of terms, 2
1

Hearing protectors, 2
18

Moving machine components, 2
45

Protective gloves, 2
19

Observing, 2
45

iii
 Indexofkeywords

Protective goggles, 2
19 Responsibility of the machine opera- Space requirement, For truck mixers,

Safety footwear, 2
18 tor, 2
15 5
11

Safety harness, 2
19 Restrictions, Cold weather, 2
39 SPC, SPC display, 3
27

Safety helmet, 2
18
Retesting (safety inspection), 2
9 SPC display
Protective gloves, 2
19
All symbols in the menu bar, 3
33,
Reverse pumping, Description of the
Protective goggles, 2
19 functions, 3
13 3
44

All symbols in the menu bar in the in

Pump, Description of the functions, Riser, 5
26
puts and outputs menu, 3
57
3
12
Rotor gearbox, Transmission oil, 7
17
All symbols in the menu bar in the lu

Pump control system, 3
76, 6
17
Rotor pumps, Pump tube grease, brication menu, 3
54
Pump functions 7
18
Battery charging control, 3
38

Stroke length, 4
10
CAN bus communication CAN1, 3
37

Stroke time, 4
10
CAN bus communication CAN2, 3
38
Pump tube in rotor pumps, Grease,
S
Coolant level, 3
37
7
18
Delivery rate, 3
40
S transfer tube

EMERGENCY STOP, 3
39
Pumping operations, 2
44
Adjusting, 7
107

Engine oil pressure, 3
37

Blockages, 6
12
Description of the functions, 3
13

Engine oil temperature, 3
37

Breaks in pumping, 6
13
Measuring the wall thickness, 7
125

Engine status, 3
37

Concrete properties, 6
6
Prestressing, 7
110

EOC, 3
40

Cooling, 6
15
Replacing, 7
85

Ergonic Output Control, 3
59

Diesel engine, 6
14
Switching overlap, 7
112

Expanded HOME, 3
42

Filling the agitator hopper, 6
7 S transfer tube wear sleeve, Repla-
Fault memory, 3
48

Hand signals, 6
3 cing, 7
93

Forward pumping, 3
39

Monitoring, 6
10
Safety equipment, 2
54, 3
3
Fuel filter, 3
37

Overheating, 6
14

Preconditions, 6
1 Safety footwear, 2
18
Function buttons in the expanded
HOME menu, 3
42

Pumping, 6
9 Safety harness, 2
19

Function buttons in the HOME menu,

Safety, 2
44 Safety helmet, 2
18 3
32

Saturated mix, 6
6
Safety-relevant components, 2
53
Function buttons in the inputs and out


Starting pumping, 6
8 puts menu, 3
56
Service life, 3
15

Function buttons in the lubrication
Set–up site, 2
25, 2
27
Q
High−voltage lines, 2
21
menu, 3
53

Function buttons in the user settings

Supports, 2
30
Qualifications, 2
15 menu, 3
50
Set-up site, 5
10
HOME, 3
32
Qualified personnel, Definition of
terms, 2
3
Accessibility, 5
11
Hydraulic fluid overheating, 3
38

Approach route, 5
11
Inputs and outputs, 3
56

Approach route for truck mixers, 5
11
Instruments in the expanded HOME
R
Minimum clearance from pits, 5
13 menu, 3
43

Space for truck mixers, 5
11
Instruments in the HOME menu, 3
35
Rating plate, Machine, 3
7
Supporting ground, 5
12
Lubrication, 3
41, 3
53
Reaches, Extending, 2
11 Setting up, Machine, 5
14
Operating data, 3
46
Ready for operation
Pump status, 3
39
Signaller, Definition of terms, 2
2

Checking, 2
20
Reverse pumping, 3
39
Site of use, 3
16
S transfer tube switch
over, 3
40

Rendering the machine ready, 2
20
SK delivery line system, 5
27
Sensors, 3
38
Regulations, 2
16, 2
17
Slewing gear transmission, Transmis-
Software information, 3
45
Remote control, 2
44, 6
2
Start screen, 3
31
sion oil, 7
17

Cable remote control, 3
63
Symbols in the expanded HOME
Software, 2
54
Removing obstacles, 2
11 menu, 3
44
Sound power level, 3
8
Symbols in the HOME menu, 3
36
Respiratory protection, 2
19
Sound pressure level, 3
8
User settings, 3
49

iv
 Indexofkeywords

Vibrator, 3
41 Technical terms, G
15 Use contrary to designated use, 2
11
SPC display unit, 3
27 Temperatures, 3
17
Accessories and attachments, 2
14

Operating elements, 3
24, 3
27
Restrictions, 2
39
Climbing the placing boom, 2
13

Exclusion of liability, 2
14
Special work, 2
50 Test run, 4
6

Extending the reach, 2
11
Spectacle wear plate, Replacing, 7
71
Diesel engine, 4
7

Extensions, 2
12

Machine, 4
7
Starting pumping, 6
8
High−pressure delivery, 2
14
Thrust ring, Replacing, 7
101
Impermissible end hose, 2
12
Static base structure, 3
11, 5
7
Tightening torques
Impermissible working area, 2
13
Stationary booms, 2
25

Flared screwed joint, 7
11
Lifting loads, 2
11
Stationary delivery line, 5
19
General, 7
10
Removing obstacles, 2
11

Danger zone, 5
20
Profiled ring joint, 7
11
Transporting goods, 2
11

Downpipe, 5
26
Set screws and nuts, 7
10

Fastening, 5
23
Towing, 2
33

Fixed point, 5
24 V

Horizontal, 5
23 Transfer gearbox, Transmission oil,
7
17 Vacuum meter, Venting, 7
35

Instructions for laying the line, 5
21

Riser, 5
26 Transfer tube bearing, Replacing, Value preservation of machines in

SK delivery line system, 5
27 7
49 storage, 6
43

Vertical and inclined, 5
25 Transfer tube change-over valves, Vibrator, 3
80, 4
19
Stationary machines, 2
25 Emergency operation, 6
17 Visual checks, 4
1, 7
23

Lifting machines, 2
26 Transition liner, Replacing the inter-
Condensate water, 4
3

Loading, 2
26 mediate rings, 7
76
Functional fluids, 4
2

Set−up site, 2
25 Transmission oil
Hydraulic fluid radiator, 4
3

Stationary booms, 2
25
Agitator gearbox, 7
17
Hydraulic system, 4
1

Transporting, 2
26
Rotor gearbox, 7
17
Lubrication points, 4
3
Storm, 2
39
Slewing gear transmission, 7
17
Parts in contact with concrete, 4
5

Transfer gearbox, 7
17
Water box, 4
4
Subject expert, Definition of terms,
2
3 Transport, 5
1
Suction cleaning, 6
30
Chassis, 5
4

Crawler track, 5
7
W
Suction filter, 3
77

Driving with an F 8 chassis, 5
4 Wash–out adaptors, 6
24
Support legs, Description of the func-
Driving with an F25 chassis, 5
4 Water, 2
49
tions, 3
11
Driving with an F80 chassis, 5
5
Water box, 4
4
Support legs and support feet, Dan-
Loading, 5
1

Description of the functions, 3
13
ger zone, 2
7
Transporting, 2
26
Water hose, Marking, 6
27
Supporting ground, 2
28, 5
12
Transporting goods, 2
11

Corner bearing loads, 2
29 Wear ring, Replacing, 7
101
Truck mixer, 2
45
Supports, 2
30 Welding, 2
52

Definition of terms, 2
2
Switching shaft bearing, Replacing, Wind speeds, 2
39
Truck mixer driver, 2
45
7
55

Definition of terms, 2
3 Working area, 2
4, 2
6
Symbols, 1
3
Impermissible working area, 2
5, 2
6,
Two–layer delivery line elbow, Inspec- 2
13
Symbols for the control system, G
1 tion, 7
132

Permitted working area, 2
5
Two–layer delivery pipe, Inspection,
Working with the machine
T 7
132

Before starting work, 2
20

Checking that the machine is ready for
T–delivery pipe with wash–out port,
6
25 U operation, 2
20

Rendering the machine ready for ope

Technical data, 3
5 Unexpected restart, Agitator safety ration, 2
20

Sound power level, 3
8 cutout, 4
14

Sound pressure level, 3
8

v
 9 Glossary

This chapter illustrates the control system symbols (icons for con

crete pumps) and explains the abbreviations and technical terms
that are used in Putzmeister Operating Instructions.

BP14_001_0501EN
 Glossary

G–1 Symbols for concrete pumps in accordance with German Mechanical Engineering
Association Standard (VDMA 24119)

G–1.1 General (for key, see page G — 7)

3701 3713 3725 5008 6012 7005

3702 3714 4001 6001 6013 7006

3703 3715 4002 6002 6014 7007

3704 3716 4003 6003 6015 7008

3705 3717 4004 6004 6016 7009

3706 3718 5001 6005 PM6017 7010

3707 3719 5002 6006 PM6018 7011

3708 3720 5003 6007 PM6019 7012

3709 3721 5004 6008 7001 8001

3710 3722 5005 6009 7002 8002

3711 3723 5006 6010 7003 8003

3712 3724 5007 6011 7004 8004

BP14_003_0501EN G1
 Glossary

8005 10005 10017 12001 12013 12025

8006 10006 10018 12002 12014 12026

8007 10007 10019 12003 12015 12027

8008 10008 10020 12004 12016 12028

8009 10009 10021 12005 12017 12029

9001 10010 10022 12006 12018 12030

9002 10011 10023 12007 12019 12031

9003 10012 10024 12008 12020 12032

10001 10013 10025 12009 12021 12033

10002 10014 11001 12010 12022 12034

10003 10015 11002 12011 12023 12035

10004 10016 11003 12012 12024 12036

G2 BP14_003_0501EN
 Glossary

12037 12043 12049 12055 13004 14003

12038 12044 12050 12056 PM13005 15001

12039 12045 12051 12057 PM13006 15002

12040 12046 12052 13001 PM13007 15003

12041 12047 12053 13002 14001

12042 12048 12054 13003 14002

G–1.2 Support (for key, see page G — 10)

2601 2604 2607 2610 2613 2616

2602 2605 2608 2611 2614 2617

2603 2606 2609 2612 2615

BP14_003_0501EN G3
 Glossary

G–1.3 Boom, 2–arm (for key, see page G — 10)

1201 1203 1205 1207 1209 1211

1202 1204 1206 1208 1210

G–1.4 Boom, 3–arm (for key, see page G — 10)

1301 1304 1307 1310 1313 1316

1302 1305 1308 1311 1314

1303 1306 1309 1312 1315

G–1.5 Boom, 4–arm (for key, see page G — 11)

1401 1406 1411 1416 1421 1426

1402 1407 1412 1417 1422 1427

1403 1408 1413 1418 1423

1404 1409 1414 1419 1424

1405 1410 1415 1420 1425

G4 BP14_003_0501EN
 Glossary

G–1.6 Boom, 5–arm (for key, see page G — 12)

1501 1506 1511 1516 1521 1526

1502 1507 1512 1517 1522 1527

1503 1508 1513 1518 1523 1528

1504 1509 1514 1519 1524 1529

1505 1510 1515 1520 1525 1530

G–1.7 Boom, 6–arm (for key, see page G — 12)

PM1601 PM1604 PM1607 PM1610 PM1613 PM1616

PM1602 PM1605 PM1608 PM1611 PM1614

PM1603 PM1606 PM1609 PM1612 PM1615

BP14_003_0501EN G5
 Glossary

G–1.8 Ergonic Boom Control, 3–arm (for key, see page G — 13)

PM1301 PM1303 PM1305 PM1307 PM1309

PM1302 PM1304 PM1306 PM1308

G–1.9 Ergonic Boom Control, 4–arm (for key, see page G — 13)

PM1401 PM1403 PM1405 PM1407 PM1409 PM1412

PM1402 PM1403A PM1406 PM1407A PM1410 PM1413

PM1402A PM1404 PM1406A PM1408 PM1411 PM1414

G–1.10 Ergonic Boom Control, 5–arm (for key, see page G — 14)

PM1501 PM1503 PM1505 PM1507 PM1509 PM1512

PM1502 PM1503A PM1506 PM1507A PM1510 PM1513

PM1502A PM1504 PM1506A PM1508 PM1511 PM1514

G–1.11 Ergonic Boom Control, 6–arm (for key, see page G — 14)

PM1601 PM1603 PM1605 PM1607 PM1609 PM1611

PM1602 PM1604 PM1606 PM1608 PM1610

G6 BP14_003_0501EN
 Glossary

G–2 Key to the symbols for concrete pumps

G–2.1 General
3701 Increase/reduce output using rotarycontroller 5001 Agitator, hopper

3702 Increase/reduce output using toggleswitch 5002 Agitator clockwise rotation

3703 Increase output 5003 Agitator anticlockwise rotation

3704 Reduce output 5004 Hopper empty

3705 Reverse pumping 5005 Hopper full

3706 Pumping On 5006 Agitator cut−out

3707 Pumping Off 5007 Hopper level control

3708 Pumping On−Off 5008 High−pressure agitator

3709 Pumping standby 6001 Hydraulic oil excess temperature

3710 Pumping in general 6002 Radiator

3711 Rotor pump in general 6003 Radiator1

3712 Pump flow meter 6004 Radiator2

3713 Full output 6005 Fill accumulator

3714 Half output 6006 Dump accumulator pressure

3715 High pressure pump 6007 Hydraulic cylinder blockage

3716 Pump control system 6008 High−pressure hydraulic system

3717 Change−over 6009 Insufficient hydraulic fluid

3718 Stroke pulse change−over 6010 Hydraulic fluid

3719 Stroke correction 6011 Air

3720 Change−over delay 6012 High pressure

3721 Screw conveyor1 anticlockwise rotation 6013 Accumulator pressure

3722 Screw conveyor1 clockwise rotation 6014 Filter element

3723 Screw conveyor2 anticlockwise rotation 6015 Rod side

3724 Screw conveyor2 clockwise rotation 6016 Piston side

3725 Screw conveyor PM6017 Hydraulic fluid filter water level STOP

4001 Centralised grease lubrication, manual PM6018 Hydraulic fluid filter water level warning

4002 Centralised grease lubrication, automatic PM6019 Hydraulic fluid filter contamination warning

4003 Centralised oil lubrication, manual 7001 Working light

4004 Centralised oil lubrication, automatic 7002 Lighting

BP14_004_0905EN G7
 Glossary

7003 Control cabinet lighting 10010 Speed sensor

7004 Toolbox lighting 10011 Increase speed

7005 Rear light 10012 Reduce speed

7006 Spirit level lighting 10013 Engine air filter

7007 Flashing beacon 10014 Electric motor in general

7008 Acknowledge flashing beacon 10015 Silent

7009 Brake light 10016 Reduced fuel consumption

7010 Side marker lamps container 10017 Tank monitoring

7011 Lighting mast 10018 Coolant level

7012 Diagnostics lamp 10019 Diesel engine control

8001 Machine diagnostics connector 10020 Starter

8002 Read−out data 10021 Manual throttle lever

8003 Read−in data 10022 Start−up relief (soft start)

8004 Read−in minimum value 10023 Diesel supply On

8005 Reset memory contents (save) 10024 Fuel

8006 Cancel memory contents (clear) 10025 Fuel filter draining

8007 Start 11001 Radio remote control

8008 Read−in maximum value 11002 Remote control in general

8009 Menu 11003 Plug in remote control

9001 Control cabinet 12001 Horn

9002 Diagnostics socket 12002 Fault in general

9003 Teleservice 12003 Acknowledge

10001 Diesel engine On 12004 Battery

10002 Diesel engine Off 12005 Battery charging device

10003 Engine oil excess temperature 12006 EMERGENCY STOP activated

10004 Cooling water excess temperature 12007 Acknowledge EMERGENCY STOP

10005 Acknowledge cooling water excess temperature 12008 Stop

10006 Engine oil pressure 12009 Test operation

10007 V−belt failure 12010 Vibrator On

10008 Increase speed, reduce speed 12011 Vibrator Off

10009 Speed 12012 Vibrator

G8 BP14_004_0905EN
 Glossary

12013 Potentiometer 12042 Lock

12014 Off−On 12043 2ndlevel

12015 On 12044 Circuit1

12016 Off 12045 Circuit2

12017 Fast (e.g.acceleration) 12046 Circuits1+2

12018 Normal (e.g.acceleration) 12047 High−pressure limit

12019 Compressor 12048 Flap/closure closed

12020 Compressor On−Off 12049 Flap/closure open

12021 Motor vehicle fuse 12050 Generator

12022 Cable drum 12051 Boom on cradle

12023 Operating hours meter 12052 Manual operation

12024 Operating position 12053 Electrical levelling

12025 Electrical power 12054 See Operating Instructions

12026 Automatic/manual 12055 Wear measurement

12027 Automatic operation 12056 Water

12028 Close shut−off device 12057 Overhead roll−and−fold boom

12029 Open shut−off device 13001 Power take−off

12030 Water tank heating 13002 Truck in general

12031 Cleaning 13003 Plan view

12032 Levelling control in general 13004 Brake in general

12033 Excess pressure PM13005 Driving

12034 Fuse test PM13006 Lifting axle raised

12035 Timer relay PM13007 Lifting axle not raised

12036 Right side 14001 Mixer in general

12037 Left side 14002 Drain mixer

12038 Concrete brake 14003 Activate mixer

12039 Buzzer 15001 Water glass dosing pump

12040 Container 15002 Flushing water pump

12041 Position at the machine 15003 High−pressure water pump

BP14_004_0905EN G9
 Glossary

G–2.2 Support
2601 Support leg/foot retract/extend 2610 Support leg working light

2602 Extend support leg 2611 Support leg retract/extend

2603 Retract support leg 2612 Support foot retract/extend

2604 Lower support foot 2613 Side marker lamps support leg

2605 Raise support foot 2614 Working range on the right

2606 Swing out right support leg 2615 Working range on the left

2607 Swing in right support leg 2616 Enable stability monitoring

2608 Swing out left support leg 2617 Stability monitoring

2609 Swing in left support leg

G–2.3 Boom, 2–arm

1201 Boom in general 1207 Slew boom to the left

1202 Arm 1 up 1208 Slew boom to the right

1203 Arm 1 down 1209 Move arms

1204 Arm 2 up 1210 Move arms switched off

1205 Arm 2 down 1211 Slewing gear activated

1206 Boom activated

G–2.4 Boom, 3–arm

1301 Boom in general 1309 Slew boom to the left

1302 Arm 1 up 1310 Slew boom to the right

1303 Arm 1 down 1311 Move arms

1304 Arm 2 up 1312 Move arms switched off

1305 Arm 2 down 1313 Slewing gear activated

1306 Arm 3 up 1314 Slew boom to the right switched off

1307 Arm 3 down 1315 Slew boom to the left switched off

1308 Boom activated 1316 Arm1 down switched off

G10 BP14_004_0905EN
 Glossary

G–2.5 Boom, 4–arm

1401 Boom in general 1415 Slewing gear activated

1402 Arm 1 up 1416 Arms up switched off

1403 Arm 1 down 1417 Slew boom to the left switched off

1404 Arm 2 up 1418 Slew boom to the right switched off

1405 Arm 2 down 1419 Arm1 down switched off

1406 Arm 3 up 1420 Arms up switched on

1407 Arm 3 down 1421 Tilt switch, arm1 circuit1

1408 Arm 4 up 1422 Tilt switch, arm1 circuit2

1409 Arm 4 down 1423 Tilt switch, arm2 circuit1

1410 Boom activated 1424 Tilt switch, arm2 circuit2

1411 Slew boom to the left 1425 Pressure switch, arm1 circuit1

1412 Slew boom to the right 1426 Pressure switch, arm1 circuit2

1413 Move arms 1427 Unfolding position

1414 Move arms switched off

BP14_004_0905EN G11
 Glossary

G–2.6 Boom, 5–arm

1501 Boom in general 1516 Move arms

1502 Arm 1 up 1517 Move arms switched off

1503 Arm 1 down 1518 Slew boom to the left switched off

1504 Arm 2 up 1519 Slew boom to the right switched off

1505 Arm 2 down 1520 Arm1 down switched off

1506 Arm 3 up 1521 Arms up switched on

1507 Arm 3 down 1522 Tilt switch, arm1 circuit1

1508 Arm 4 up 1523 Tilt switch, arm1 circuit2

1509 Arm 4 down 1524 Tilt switch, arm2 circuit1

1510 Arm 5 up 1525 Tilt switch, arm2 circuit2

1511 Arm 5 down 1526 Pressure switch, arm1 circuit1

1512 Boom activated 1527 Pressure switch, arm1 circuit2

1513 Slew boom to the left 1528 Unfolding position

1514 Slew boom to the right 1529 Arm5 switched on

1515 Slewing gear activated 1530 Arm5 switched off

G–2.7 Boom, 6–arm

PM1601 Boom in general PM1609 Arm 4 down

PM1602 Arm 1 up PM1610 Arm 5 up

PM1603 Arm 1 down PM1611 Arm 5 down

PM1604 Arm 2 up PM1612 Arm 6 up

PM1605 Arm 2 down PM1613 Arm 6 down

PM1606 Arm 3 up PM1614 Boom activated

PM1607 Arm 3 down PM1615 Slew boom to the left

PM1608 Arm 4 up PM1616 Slew boom to the right

G12 BP14_004_0905EN
 Glossary

G–2.8 Ergonic Boom Control, 3–arm

PM1301 Move end hose PM1306 Unfold the placing boom

PM1302 End hose forwards PM1307 Fold the placing boom

PM1303 End hose back PM1608 End hose to the left

PM1304 End hose up PM1309 End hose to the right

PM1305 End hose down

G–2.9 Ergonic Boom Control, 4–arm

PM1401 Move end hose PM1407 Fold the placing boom

PM1402 End hose forwards PM1407A Fold the placing boom (USA)

PM1402A End hose forwards (USA) PM1408 End hose to the left

PM1403 End hose back PM1409 End hose to the right

PM1403A End hose back (USA) PM1410 Upper limit

PM1404 End hose up PM1411 Lower limit

PM1405 End hose down PM1412 Preferred position for arm 1

PM1406 Unfold the placing boom PM1413 Preferred position for arm 4

PM1406A Unfold the placing boom (USA) PM1414 Preferred position arm1 + arm4

BP14_004_0905EN G13
 Glossary

G–2.10 Ergonic Boom Control, 5–arm

PM1501 Move end hose PM1507 Fold the placing boom

PM1502 End hose forwards PM1507A Fold the placing boom (USA)

PM1502A End hose forwards (USA) PM1508 End hose to the left

PM1503 End hose back PM1509 End hose to the right

PM1503A End hose back (USA) PM1510 Upper limit

PM1504 End hose up PM1511 Lower limit

PM1505 End hose down PM1512 Preferred position for arm 1

PM1506 Unfold the placing boom PM1513 Preferred position for arm 5

PM1506A Unfold the placing boom (USA) PM1514 Preferred position arm1 + arm5

G–2.11 Ergonic Boom Control, 6–arm

PM1601 Move end hose PM1607 Fold the placing boom

PM1602 End hose forwards PM1608 End hose to the left

PM1603 End hose back PM1609 End hose to the right

PM1604 End hose up PM1610 End hose back

PM1605 End hose down PM1611 End hose forwards

PM1606 Unfold the placing boom

G14 BP14_004_0905EN
 Glossary

G–3 Abbreviations and technical terms

ADR Arbeitsdrehzahlregelung → Speed of rotation regulation

Agitator safety cutout The agitator safety cutout automatically cuts power to the agitator
and the concrete pump when the grille is opened.

APP → Automatic Piston Pull

Arc configuration Variant of boom movement in Ergonic Boom Control mode on

machines with a Z fold system: the position of the arm assembly
resembles an arc.

Automatic Piston Pull A ball cock is fitted in the drive cylinder. When the ball cock is
closed, you can pull the delivery piston out of the delivery cylinder
to replace it.

Blockage Blockage in the delivery line: the concrete behind the blockage
cannot continue to flow. The blockage may occur due to wedging
caused by coarse particles, etc.

Change−over Reversal of direction of the delivery piston in the middle of a stroke

movement: The → transfer tube switches over. The concrete is still
pumped without interruption.

Change−over delay throttle The change−over delay throttle is a hydraulic component which
delays the change−over of the → transfer tube.

Check book The check book is part of the documentation accompanying the
machine: checklist with confirmation of the legally required checks
for concrete pumps and placing booms

Corner bearing load The corner bearing load is the force transferred to the ground
through each support foot.

BP14_002_0501EN G15
 Glossary

dB Decibels: unit of measurement for the → sound power level

dB (A) Decibels (A): unit of measurement for the → sound pressure level

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 which

control concrete pumps and placing booms.

Ergonic Boom Control Microprocessor supported system for controlling and regulating
the placing boom. Among other functions, EBC allows you to move
the placing boom using just one joystick.

Ergonic Graphic Display Graphic display in the control cabinet door. The operating state of
the machine is shown in the display. You may also be able to set
functions here, depending on the equipment on your machine.

Ergonic Graphic Display  Graphic display in the remote control. The operating state of the
Remote Control machine is shown in the display. You may also be able to set
functions here, depending on the equipment on your machine.

Ergonic Output Control Microprocessor supported system for economic operation of

theconcrete pump. The minimum engine speed required for
thedelivery rate selected by the operator is automatically set.

Ergonic Pump System Microprocessor supported system for controlling and regulating
the concrete pump. Among other functions, EPS allows you to
restrict the concrete pressure and delivery rate.

G16 BP14_002_0501EN
 Glossary

FFH → Free−Flow Hydraulics

Free−Flow Hydraulics Free−Flow Hydraulics is a type of drive for the concrete pump
which switches the fluid flow from the main pump directly to the
drive cylinders, i.e. there is free fluid flow without interposed
valves.

Fully hydraulic control Fully hydraulic control is a type of control of the concrete pump
which switches the fluid flow from the main pump to the drive
cylinder using valves (closed hydraulic circuit).

Functional fluids Hydraulic fluid, fuel, brake fluid, battery acid etc.

Grille The grille is the protective cover for the hopper and has two
functions:
− Allowing only particles up to a certain size to pass
− Protecting persons against reaching into the hopper

KEP Kolben−Endlagen−Positionierung → Piston end−of−travel

positioning

Lela → Levelled last arm

Level control Level control controls the amount of concrete in the hopper during
pumping operations using a fill−level sensor.

Levelled last arm Last arm of the placing boom in a horizontal position

BP14_002_0501EN G17
 Glossary

Machine card The machine card is part of the documentation accompanying

themachine:
− List of machine components
− Circuit diagram information

Maintenance card A maintenance card describes measures and their sequence for
maintaining the machine and for replacing parts and wear parts.

Monoblock The monoblock is a hydraulic safety valve on the boom hydraulic

cylinders.

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.

One−Side−Support One−Side−Support is a type of support for supporting the machine

in narrow spaces.

Operating equipment Battery, filters

OSS → One−Side−Support

PEDOC → Putzmeister Electronic Documentation

Piston end−of−travel positioning A ball valve is fitted in the drive cylinder. When the ball valve is
closed, you can lock the drive cylinder in its end−of−travel position
to replace it.

Piston side

Proportional control Infinitely variable controller for setting the boom speed

Putzmeister Electronic Documentation accompanying the machine on CD−ROM

Documentation

G18 BP14_002_0501EN
 Glossary

Quick disconnect point Arm 1 of the arm assembly can be disconnected at the quick
disconnect point.

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 folded
in and out.

Roll configuration Position of the M 31 arm assembly in Ergonic Boom Control

operation 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 tube
The pump tube is pressed together as the pressure rollers roll
overit. This pushes the concrete in the pump tube ahead of
thepressure roller towards the rotor housing outlet and into the
delivery line.

RSA Rührwerksicherheitsabschaltung → Agitator safety cutout

BP14_002_0501EN G19
 Glossary

Service operation The Pumping operations − Service operations" toggle switch

onthe control cabinet can be used to switch over between the
concrete pump and the compressor. You can switch on the
compressor, rather than the pump, at the radio remote control if
you set the switch to Compressor".

Snaplock The snaplock is a mechanical safety device to protect against

unintentional 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 the
relative loudness of the sound [dB(A)].

Speed of rotation regulation The ADR function regulates the mixer drum speed while the truck
is being driven.

Squeeze valve The squeeze valve is a component on the end hose which closes
the delivery line when the pump is stopped.

Stroke correction The stroke is corrected automatically by the addition or removal of

hydraulic fluid through bores in the cylinder. This means that the
delivery piston can achieve its maximum stroke length. Without
stroke correction, the delivery piston would not always reach its
end 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 for
supporting the machine.

Support foot plate The support foot plate is a component on the underside of the
support foot.

G20 BP14_002_0501EN
 Glossary

Teach−in Specialist word for storing in memory

Test reading The test reading is part of the documentation accompanying the
machine: list of machine setting values

to trigger The magnetic switches are triggered, i.e. when an object is

brought near, they switch without any contact being made.

Transfer tube The transfer tube is a component which is swung between the two
delivery cylinders in the hopper. It is the connection between the
delivery cylinder and the delivery line.

UVD Umsteuer−Verzögerungsdrossel → Change−over delay throttle

VHS Vollhydraulische Steuerung → Fully hydraulic control

Z fold system Type of folding of the arm assembly: the arm assembly resembles
the letter Z when folded in and out.

Z configuration Variant of boom movement in Ergonic Boom Control mode on

machines with a Z fold system: the position of the arm assembly
resembles the letter Z.

BP14_002_0501EN G21
 Glossary

G22 BP14_002_0501EN