Manual Operating & Maintenance Instructions BSF 36-4.12L

Operating Instructions
BSF 36-4.12L
210603466
A820062 E
Table of contents
INHV
Guide to the Operating Instructions . 11
1.1
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2
Icons and symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Safety Regulations . . . . . . . . . . . . . . . 21
2.1
Personnel Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.2
Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.3
2.3.1
2.3.2
2.3.3
2.3.4
2.3.5
2.3.6
Use contrary to the designated use . . . . . . . . . . . . . . . . . . .

Lifting loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Extending the end hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
End hose with spout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Extending the reach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standing on the placing boom . . . . . . . . . . . . . . . . . . . . . . . . .
Exclusion of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Technical Description . . . . . 31
3.1
36Z Overview Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.2
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.3
Machine Rating Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.4
Boom Rating Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.5
36Z Range Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.6
3.6.1
3.6.2
3.6.3
3.6.4
3.6.5
3.6.6
Description of the Functions . . . . . . . . . . . . . . . . . . . . . . . . .

Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Delivery Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Concrete Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
S Transfer Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.7
3.7.1
Symbols for the Control System . . . . . . . . . . . . . . . . . . . . . . 38

Concrete Pump (Part 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
25
25
26
26
27
28
29
36
36
36
36
36
37
37
Table of contents
II
3.7.2
3.7.3
3.7.4
3.7.5
3.7.6
3.7.7
3.7.8
Concrete Pump (Part 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical System (Part 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical System (Part 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
39
310
311
312
313
313
314
3.8
3.8.1
3.8.2
3.8.3
3.8.4
3.8.5
3.8.6
3.8.7
3.8.8
3.8.9
Electrical Control Devices . . . . . . . . . . . . . . . . . . . . . . . . . . .

Central Module Control Cabinet . . . . . . . . . . . . . . . . . . . . . . . .
Control Panel in the Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cable Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radio Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMERGENCY SHUT - DOWN Button . . . . . . . . . . . . . . . . . . .
Proximity Switch Junction Box . . . . . . . . . . . . . . . . . . . . . . . . .
Proximity Switch Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hopper Grate Cutout Device . . . . . . . . . . . . . . . . . . . . . . . . . . .
Agitator Shut - Off Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
315
316
321
326
328
334
336
338
339
341
3.9
3.9.1
3.9.2
3.9.3
3.9.4
3.9.5
342
343
344
345
346
3.9.6
Hydraulic Control Devices . . . . . . . . . . . . . . . . . . . . . . . . . . .

Outriggers Control Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boom Functions Control Block . . . . . . . . . . . . . . . . . . . . . . . . .
Agitator Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Pump Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accumulator Dump Valve, Accumulator Dump Cock,
Transfer Tube Damping Cock . . . . . . . . . . . . . . . . . . . . . . . . . .
Manual Volume Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.10
3.10.1
3.10.2
3.10.3
3.10.4
Other Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flushing Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
End hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vibrator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Fluid Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
350
350
351
354
355
Travel . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.1
4.1.1
4.1.2
4.1.3
Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Prior to Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Driving in Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
During the Journey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
347
349
42
42
42
43
INHV
Table of contents
4.2
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.3
Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Operation . . . . . . . . . . . . . . . . . . . . . . . 51
5.1
Preliminary Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5.2
5.2.1
Function Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switchover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stroke Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stroke Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filter Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vacuum Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boom Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMERGENCY SHUT - DOWN Function . . . . . . . . . . . . . . . . . .
EMERGENCY SHUT - DOWN Button . . . . . . . . . . . . . . . . . . .
Function Check on the Boom Control Unit . . . . . . . . . . . . . . .
53
53
53
53
53
53
54
54
54
55
56
56
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pre-Operation Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preliminary Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Calculation Example 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Calculation Example 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Corner Bearing Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Support Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Length of the Timber Blocks Required . . . . . . . . . . . . . . . . . .
Example 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Example 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Control Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outriggers Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
57
57
59
511
511
514
515
516
517
518
520
523
Boom Movements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Prohibited Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overlapping Working Ranges . . . . . . . . . . . . . . . . . . . . . . . . . .
Restrictions on Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bad Weather and Storms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cold Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
527
527
527
528
528
528
5.2.2
5.2.3
5.2.4
5.3
5.3.1
5.3.2
5.3.3
5.3.4
5.4
5.4.1
INHV
III
Table of contents
5.4.2
5.4.3
5.4.4
5.4.5
5.4.6
Danger Zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High - Voltage Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Signal of Boom Movements . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Temperature-Related Cylinder Movements . . . . . . . . . . . . . .
Uncontrolled Boom Movements . . . . . . . . . . . . . . . . . . . . . . . .
Countermeasures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5
Hand Signals for Boom and Pumping Operations . . . . . . 533
5.6
5.6.1
Extending the 36Z 4 - Section Boom . . . . . . . . . . . . . . . . . . . 534

Impermissible Working Range . . . . . . . . . . . . . . . . . . . . . . . . . 539
5.7
5.7.1
5.7.2
5.7.3
5.7.4
5.7.5
Pumping Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Notes on Correct Pumping . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting Pumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Possible Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blockages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Restarting After Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Cases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Continuation Delivery Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
540
540
542
544
544
546
546
547
548
549
549
5.8
5.8.1
5.8.2
5.8.3
5.8.4
5.8.5
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preparations for Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Delivery Line Cleaning Methods . . . . . . . . . . . . . . . . . . . . . . . .
Delivery Line Suction Cleaning . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning the Hopper, Delivery Cylinder, and S-Tube . . . . . .
Truck superstructure and Post - Washing Operations . . . . . .
550
550
556
558
561
564
5.9
5.9.1
5.9.2
5.9.3
Teardown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boom Teardown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outriggers Teardown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controls Teardown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
565
565
569
570
5.10
Pumping Concrete with the Emergency Stroke Kit . . . . . 572
5.7.6
IV
529
530
531
531
532
532
INHV
Table of contents
INHV
Maintenance . . . . . . . . . . . . . . . . . . . . 61
6.1
Maintenance Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
6.2
6.2.1
6.2.2
General Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Flared Screwed Joint, Reassembly . . . . . . . . . . . . . . . . . . . . . 66
Profiled Ring Joint, Reassembly . . . . . . . . . . . . . . . . . . . . . . . . 66
6.3
6.3.1
6.3.2
6.3.3
6.3.4
6.3.5
6.3.6
6.3.7
6.3.8
Functional Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil for the Power Take - Off (PTO), Rotor and
Agitator Gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manual Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Centralized Lubrication System . . . . . . . . . . . . . . . . . . . . . . . .
Truck Engine Oil and Transmission Oil . . . . . . . . . . . . . . . . . .
Level of Contaminant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubricant Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Storage of Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4
6.4.1
6.4.2
Recommended Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . 610

Hydraulic Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 612
Oils and Greases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 612
6.5
Visual Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 615
6.6
Changing the Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . 617
6.7
Function Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623
6.8
6.8.1
6.8.2
6.8.3
6.8.4
Performing Maintenance on the Accumulator . . . . . . . . .

Checking Accumulator Pre-Charge Pressure . . . . . . . . . . . .
Decreasing Accumulator Pressure . . . . . . . . . . . . . . . . . . . . . .
Increasing Accumulator Pressure . . . . . . . . . . . . . . . . . . . . . . .
Replacing Accumulator Bladder . . . . . . . . . . . . . . . . . . . . . . . .
6.9
Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 631
6.10
Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 639
6.11
Vacuum Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 643
6.12
Change of Delivery Piston with KEP . . . . . . . . . . . . . . . . . . 645
6.13
Lubricating the S Transfer Tube . . . . . . . . . . . . . . . . . . . . . . 655
67
67
68
68
68
68
69
69
69
625
628
629
629
630
Table of contents
VI
6.14
S transfer tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 57
S transfer tube variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 58
6.15
Measuring the Wall Thickness

(Machines with S Transfer Tube) . . . . . . . . . . . . . . . . . . . . . . 681
6.16
Lubricating the M 36Z Placing Boom . . . . . . . . . . . . . . . . . 687
6.17
Lubricating the Boom Pedestal (TRDI 70) . . . . . . . . . . . . . 689

Lubrication Points with No Central Lubrication Manifold . . . 690
Lubrication Points with Central Lubrication Manifold . . . . . . 690
6.18
Replacing the Delivery Line . . . . . . . . . . . . . . . . . . . . . . . . . . 691
Troubleshooting Guide . . . . . . . . . . . 71
7.1
Concrete Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
7.2
Placing Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
7.3
Boom Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
7.4
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
INHV
1
1.1
Foreword
Guide to the Operating Instructions

These Operating Instructions are intended to familiarize the user with
the machine and to assist them in using the machine properly in various
operations.
The Operating Instructions contain important information on how to
operate the machine safely, properly, and efficiently. 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 are to be supplemented by the respective
state, local, and national rules and regulations for accident prevention
and environmental 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
in charge of carrying out work with and on the machine, such as:
Operation, including setting up, troubleshooting in the course of
work, or tearing down the machine
Service (maintenance, inspection, repair)
Transport
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, the generally recognized rules
of technology for safe and proper working must also be observed.
A820062_01_0208D
11
Should you have any questions following your study of the Operating
Instructions, the Branch or Agency serving you, or Putzmeister
America in Racine, WI will be happy to give you more information.
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 serial
number.
In the interest of constant improvement, modifications are made from
time to time and it could be possible that we were unable to take these
into consideration when these Operating Instructions were printed.
All product descriptions, illustrations and specifications were in effect
at the time the manual was released for printing. Putzmeister reserves
the right to make changes in design or to make additions to or
improvements in its products without imposing any obligations upon
itself to install them on products previously manufactured.
The contents of this publication may not be reproduced, even in
extract, without our written permission. All technical data, drawings,
etc. are protected by copyright.
E copyright by
12
A820062_01_0208D
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, generally from top to bottom in the sequence shown.
Text following this symbol describes the result or effect of an action.

Refer also to the maintenance cards:
This symbol 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 information regarding environmental protection is
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 with the icon illustrated, the word Note printed in bold, and
a line. 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 with the icon illustrated, the word Danger
printed in bold, and a line. The associated text is printed in italics and
ends with another line.
A820062_01_0208D
13
Danger
Particular information or rules or prohibitions intended to prevent
injury or significant damage are introduced with the icon illustrated,
the word Danger printed in bold, and a line. The associated text is
printed in italics and ends with another line.
The appropriate symbol will be used if it is possible to identify the

source of the danger precisely.
Danger of fire
This symbol is used to identify tasks for which there is a particular danger of fire.
Danger of explosion
This symbol is used to identify tasks during which there is the danger of
an explosion. The explosion may also be caused by pressure being released suddenly.
Falling items
This symbol is used to identify tasks in which there is a danger of injury
caused by parts falling down.
Danger of crushing
This symbol is used to identify tasks during which there is the danger of
being crushed.
14
A820062_01_0208D
Suspended load
This symbol is used to identify tasks in which suspended loads may fall
down.
High voltage
This symbol is used to identify tasks in which there is the danger of
electrocution, possibly with lethal consequences.
Danger of burning
This symbol is used to identify tasks in which there is a danger of burning from chemical substances which are not specifically described.
Danger of burning
This symbol is used to identify tasks in which there is a danger of burning from battery acid.
Danger of poisoning
This symbol is used to identify tasks in which there is a danger of poisoning by inhalation of gases, ingestion of or contact with substances.
A820062_01_0208D
15
16
A820062_01_0208D
Safety Regulations
Putzmeister America cannot anticipate every possible circumstance
that might involve a potential hazard. The warnings in this manual are
therefore not all inclusive. If a procedure, tool, device, or work method
not specifically recommended by Putzmeister is used, you must satisfy
yourself that it is safe for you and others. You should also ensure that
the machine will not be damaged or made unsafe by the procedures
you choose.
Each truck-mounted concrete pump has undergone a thorough Quality
Control inspection at the factory. The design incorporates built-in
safety features, however it can be potentially dangerous in the hands of
untrained or careless operators.
Knowing the characteristics of the machine and function of the controls
is important for safe, proper operation, and use. Becoming familiar
with the controls and practices of concrete pumping will result in
efficient and smooth pumping.
This topic:
A820062_02_0208D
Starts on page:
2.1 Personnel Qualifications
22
2.2 Safety Regulations
22
21
Safety Regulations
2.1
Personnel
Qualifications
Only qualified personnel must be allowed to operate, repair, or

troubleshoot the truck-mounted concrete pump:
A qualified operator is one who has read and understood the
instructions in this manual and is thoroughly familiar with the
operating characteristics and limitations of the machine.
Qualified operators must:
-- Read and have a thorough understanding of all precautions
mentioned in the Safety Booklet for Concrete Pump
Operators (BP1742GB--3).
-- Know and follow all decals and operating instructions.
-- Understand and obey all applicable Local and Government
statutes and regulations applying to safe operation and use of
concrete pumping machines.
-- Report any damage, defects, problems, or accidents to their
supervisor immediately.
Repair and adjustments must only be made by qualified personnel.
All personnel assigned to repair or troubleshoot the truck-mounted
concrete pump must be thoroughly familiar with and understand the
job they are about to do. If in doubt, use extreme caution and obtain
assistance from other trained/qualified personnel. Problems may
arise that seem singular but may be due to several causes.
2.2
Safety Regulations
All personnel operating, assembling, transporting, or maintaining a

truck-mounted concrete pump should be aware of and comply with the
following safety regulations:
No modification is to be made to the machine without prior written
consent of the Putzmeister Technical Support or Engineering
Department.
While operating the unit, wear personal protective equipment (safety
goggles, hard hat etc.) required by Federal, State, local and job site
regulations.
Do not operate the unit unless it has been leveled and stabilized.
Do not operate a malfunctioning unit.
Keep decals and operating instructions legible and readable.
Make sure safety devices are in good operating condition.
Do not clean, oil, adjust, or service unit while it is operating.
Use extreme caution when handling delivery system. The
truck-mounted concrete pump is capable of delivering very high
pressures. Pressure can remain in the delivery system even after the
unit is shut down.
22
A820062_02_0208D
Safety Regulations
Never remove the hopper grate cover when the pump is in operation.
A820062_02_0208D
It protects against accidental contact with the remixer shaft and other
moving parts inside the hopper.
Never enter the hopper with any part of your body; it is a danger
area and physical injury can occur, even if the engine is stopped.
Do not stand on the hopper grate.
If work must be performed inside the hopper, ensure that engine is
OFF and accumulator pressure reads zero. The system uses a
hydraulic accumulator which contains a stored charge of high
pressure oil to shift the S-tube. On all machines, ensure that the
accumulator is depressurized.
Since hydraulic oil systems can be dangerous, know the circuit you
are repairing. It may contain high pressure and injury could occur. If
in doubt, stop the machine and allow sufficient time for the oil
pressure to decrease to zero. Check pressure gauges to confirm that
they read zero.
Do not open the concrete delivery system without relieving the
pressure. Normally, pressure can be relieved by reversing the pump
and pumping backwards. However, in the event of a rock jam,
reversing the pump may not relieve the pressure under all
conditions.
When hydraulic cylinders are used to hold loads, do not loosen
fittings without mechanically supporting the load. Loosening of
fittings may result in high pressure fluid leaks and movement of the
cylinder.
Do not fill the fuel tank while the engine is running or hot. Avoid the
possibility of spilled fuel, which may cause a fire.
If a fuel spill occurs, do not restart the engine until all spilled fuel
has been cleaned up.
Do not pour material into hopper without grate in place. Operator
must monitor material being dumped in hopper, watching for
unmixed or dry concrete, sticks, pieces of metal and other foreign
objects.
If machine is to be left unattended on a job site, secure it from
unauthorized use or movement.
Clear area before activating outriggers.
Ensure that a proper level is maintained in the hydraulic oil tank.
Oil level below minimum can cause hydraulic pump and system
damage.
23
Safety regulations
2.3
Use contrary to the

designated use
2.3.1
Lifting loads
Use other than that above or going beyond such use, such as lifting loads, for
instance, is considered contrary to the designated use. Putzmeister Werk
accepts no liability for damage resulting from such use. The risk of such
misuse lies entirely with the user.
22000600
The placing boom must never be used for lifting loads.
High--pressure delivery over 1232 psi (85 bar) concrete pressure through the
placing boom delivery line is prohibited. The delivery line and end hose are
only suitable for pressures up to 1232 psi (85 bar) in their new condition.
24
BPUS03_004_0010EN
Safety regulations
2.3.2
Extending the
end hose
Extension of the placing boom and end hose beyond the length specified on
the boom rating plate is forbidden.
42500101
Extending the end hose is not permitted.
2.3.3
End hose with spout
End hoses may not be fitted with any extension coupling, spout, swan
neck, outlet shoes or other dangerous outlet fitting or similar device.
12502000
No coupling, spout, swan neck or similar on the end of the end hose
BPUS03_004_0010EN
25
Safety regulations
2.3.4
Extending the reach
It is prohibited to attach an extension (eg freely suspended crossbeam) to the

end hose or boom tip in order to extend the reach or to pump round the
corner, so to speak. Since the boom and the lifting equipment for the
extension have differing pivotal points and modes of control, it is not
possible to coordinate their movements.
Impermissible extensions always place a load on the boom and result in
irreparable damage, as forces which the boom is not designed to withstand
are conducted into it. At worst, the boom may break or the machine could
topple over.
If, for reasons related to the site layout, pumping must be carried out over
greater reaches or in inaccessible places, it must be performed in accordance
with the Operating Instructions and a separate delivery line must be laid.
BPUS03_004_0010EN 1
26
BPUS03_004_0010EN
Safety regulations
2.3.5
Standing on the
placing boom
BPUS03_004_0010EN 2
It is forbidden to stand on the placing boom
Danger
A fall from a working height of 3.3 ft (1 m) above the ground presents a
lethal danger.
It is therefore forbidden to stand on the placing boom, to climb up it, or to
use it as a working platform or as an aid to climbing.
Always use specially designed or otherwise safety--oriented ladders and
working platforms when working at height greater than 3.3 ft (1 m) above
the ground. You must wear a safety harness when working at greater heights.
BPUS03_004_0010EN
27
Safety regulations
2.3.6
Exclusion of liability
We state here expressly that Putzmeister accepts no liability for damage

arising from incorrect or negligent operation, servicing or maintenance or as
a result of use contrary to the designated use. This statement is equally valid
for modifications to, additions to and customization of the machine which
may compromise safety. The guarantee will no longer be valid in such cases.
Please consult us should you wish to deliver higher density media. It may be
the case that suitable measures, such as reducing the reach, are necessary.
28
BPUS03_004_0010EN
General Technical Description

This topic:
Starts on page:
3.1
36Z Overview Diagram
32
3.2
Technical Data
33
3.3
Machine Rating Plate
33
3.4
Boom Rating Plate
34
3.5
36Z Range Diagram
35
3.6
Description of the Functions
36
3.7
Symbols for the Control System
38
3.8
Electrical Control Devices
315
3.9
Hydraulic Control Devices
342
3.10 Other Components
A820062_03_0208D
350
31
3.1

1
10 11
12
13
14
15 16
17

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
32
Flushing water pump (on the water tank) (page 350)

End hose (on the boom tip) (page 351)
Boom rating plate (page 34)
Radio (page 328) and/or cable control (page 326)
Documentation accompanying the product
Vibrator (on the hopper grate) (page 354)
Transfer tube (page 37)
Hopper grate cutout device (page 339)
Agitator lever (page 345) , and water pump lever (page 346)
Accumulator dump valve (page 347) and transfer tube damping cock
(page 347)
Proximity switch junction box (on the compact block) (page 336) and
manual volume control (page 349)
Outrigger pads
Hydraulic fluid radiator (one on each side) (page 355)
Outriggers control block (one on each side) (page 343)
Electric control box (page 316)
Boom control block (behind right front outrigger leg) (page 344)
Machine rating plate (page 33)
A820062_03_0208D
3.2
Technical Data
The technical data and settings for your machine are located on the
machine card and the pump and boom test reading sheets with the most
important data also provided on data plates attached to the machine and
boom.
3.3
The following rating plate is attached to the machine:
-- INC.
Racine Operation 1733 90th Street
Sturtevant, WI 53177
1
2
Made in USA
8
A800055 Rev.B

1
2
3
4
5
6
7
8
A820062_03_0208D
Model (machine model)

Serial No. (machine serial number)
Model year
Hydr. press max. [bar] (maximum fluid pressure in the hydraulic system)
Gear/Max. RPM (maximum engine speed for pumping concrete)
GVW rating [lbs] (permitted gross weight)
Concrete press. [bar] (maximum delivery pressure)
Gear/Max. RPM (maximum engine speed for pumping concrete)
33
3.4
Boom Rating Plate
The following plate is attached to the boom:
1
Putzmeister Inc.
Racine Operation
1733 90th Street
Sturtevant, WI 53177
2
3
4
5
10
mm
11
Lb/ft
bar
12
Lb/Cu.ft
bar
13
Lb/ft
PN A800002 Rev. 1
Boom Rating Plate

1
2
3
4
5
6
7
8
9
10
Boom model
Boom serial no. (machine number)
PN of arm assembly (arm assembly part number)
Model year (year of manufacture)
Horizontal reach max. (maximum horizontal reach)
Vertical reach max. (maximum vertical reach)
End hose length max. (maximum end hose length)
Max. hydr. pressure (maximum hydraulic fluid pressure)
Max. concrete pressure in delivery line
Pipe (maximum permitted pipe diameter and wall thickness of the delivery
line) [mm]
11 Max. wt. of boom pipeline WITHOUT CONCRETE
12 Max. allowable bulk density of concrete to be pumped
13 Max. wt. of boom pipeline INCLUDING CONCRETE
34
A820062_03_0208D
36Z Range Diagram
END HOSE NOT TO BE

OPERATED IN CAUTION AREA
1169
30m
985
180
20m
657
246
10m
3210
100
249
0
Vertical Reach 1169
180
104
254
288
253
Net Reach 962

365
234
20m
657
23
10m
3210
208
Horizontal Reach 104
Reach Depth 779
40m
1313
Unfolding Height 287
3.5
779
30m
985
20m
657
10m
3210
10m
3210
36Z Range Diagram
A820062_03_0208D
35
3.6
Description of
the Functions
This section is intended to help you understand the functions of the

machine so that you can restrict the field of the machines applications
to suitable areas and avoid errors in operation.
3.6.1
Boom
The boom arms are of box construction. They are actuated

hydraulically. Arm hinges with excellent angular range, in
combination with the powerful slewing gear with its wide slewing
range, provide very flexible movement.
3.6.2
Delivery Line
The delivery and riser lines comprise standard straight pipe sections
and elbows. These are thus easily replaced. Clamp couplings serve as
both pivot joints and pipe connectors. The elbow pivot at the end of the
boom acts as a brake on the falling concrete and reduces the wear on the
end hose.
3.6.3
Outriggers
The telescopic-style front outriggers and swing-out rear outriggers,

which provide the required stability, are fitted with fully hydraulic
support cylinders.
3.6.4
Hydraulic Control
All boom movements are effected hydraulically. All boom cylinders

have two integral safety valves to provide protection against
overloading or rupture of the hydraulic lines. The hydraulic fluid
supply is sufficient to operate a number of cylinders simultaneously.
The hydraulic control can be operated from the concrete pump or by
using a portable remote control unit.
The control valves are actuated:
-- electrically; or
-- electro--hydraulically.
The hydraulic fluid tank is integrated in the boom pedestal.
Compressed air and control current are taken from the truck.
36
A820062_03_0208D
3.6.5
Concrete Pump
PM concrete pumps are driven hydraulically by diesel engine powered

fluid pumps. The delivery pistons (4) are hydraulically linked together
through the driving cylinders (5). They operate in a push--pull mode.
The returning delivery piston sucks the concrete in. At the same time,
the advancing delivery piston forces the concrete sucked in previously
into the delivery line through the pressure pipe or the pressure elbow
(1). The pump switches over at the end of the stroke. The transfer tube
(2) swings over to the full delivery cylinder (3) and the delivery pistons
(4) reverse their direction of movement.
Reverse stroke
Reversal of the delivery pistons (4) movement in the middle of the
stroke movement. The transfer tube (2) does not switch. The concrete
is sucked back from the delivery line into the hopper.
Switchover
Reversal of the delivery pistons (4) direction in the middle of the
stroke movement. The transfer tube (2) switches over. The concrete is
still pumped without interruption. Switching over helps prevent the
formation of blockages.
3.6.6
S Transfer Tube
4
3
2
1
2
3
4
5
A820062_03_0208D
Pressure elbow
Transfer tube
Delivery cylinder
Delivery piston
Drive cylinder
37
3.7
Symbols for the

Control System
3.7.1
Concrete Pump (Part 1)
This section gives you a summary of the symbols used for control
actions.
10
11
12
13
14
15
No 0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
38
20007601
Designation
Pump in general
Rotor pump in general
Pump stand by
Pump On/Off
Pump on
Pump off
Reverse pumping
Stroke change--over
Increase -- reduce pumping rate (using rotary controller)
Increase -- reduce pumping rate (using toggle switch)
Increase output
Reduce output
Hare = fast
Snail = slow
Cleaning
A820062_03_0208D
3.7.2
Concrete Pump (Part 2)
10
11
12
13
14
15
16
17
20007602
No 0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
A820062_03_0208D
Designation
Agitator in general
Agitator clockwise rotation
Agitator counterclockwise rotation
Agitator safety cutout
Level control
Hopper full
Hopper empty
Water tank heating
Mixer in general
Mixer mix or fill
Mixer drain
Vibrator in general
Vibrator On
Vibrator Off
Water pump auxiliary unit
Water pump
Compressor
39
3.7.3
Engine
10
11
12
13
14
15
16
17
18
19
20007603
No 0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
310
Designation
Truck in general
Power take--off
Ignition monitoring
Diesel engine on
Diesel engine off
Charge monitor
Engine oil pressure
Silent (low noise)
Engine speed in general
Engine speed
Increase engine speed
Reduce engine speed
Tank monitoring
ECO (reduced fuel consumption)
Engine oil temperature
Coolant temperature
Coolant level
Engine fault (V--belt failure)
Air filter
A820062_03_0208D
3.7.4
Electrical System (Part 1)
10
11
12
13
14
15
16
20007604
No 0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
A820062_03_0208D
Designation
Electrical system power
Electrical system Auto--Manual
On -- Off
On
OFF
Activate EMERGENCY SHUT--DOWN
EMERGENCY SHUT--DOWN activated
Operating hours meter
Operating position (local control)
Remote control in general
Radio remote control system
Plug in remote control
Cable drum
Fault in general
Acknowledge fault
Battery
311
3.7.5
Electrical System (Part 2)
10
11
20007605
No 0
1
2
3
4
5
6
7
8
9
10
11
312
Designation
Horn
Lighting in general
Working light
All--round flashing warning light
Analogue adjustment
Level control
Electric motor
Timer relay
Fuse
Fuse test
Test operation
A820062_03_0208D
3.7.6
Hydraulic System
No 0
1
2
3
4
5
3.7.7
Designation
Hydraulic fluid temperature
Cooling fan
Close isolating gate valve (closed)
Open isolating gate valve (opened)
Excess pressure
Outriggers
20007607
No 0
1
2
3
4
5
6
7
A820062_03_0208D
Designation
Support leg function
Swing out support leg
Swing in support leg
Extend support leg
Retract support leg
Extend support foot
Retract support foot
313
3.7.8
Boom
10
11
12
13
14
15
16
20007609
No 0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
314
Designation
Boom in general
Boom functions activated
Slewing gear activated
Slew boom to the right
Slew boom to the left
Move boom
Do not move boom
Arm 1 up
Arm 1 down
Arm 2 up
Arm 2 down
Arm 3 up
Arm 3 down
Arm 4 up
Arm 4 down
Switch off arm up function
A820062_03_0208D
3.8
Electrical Control
Devices
The electrical control devices and operating elements on this 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 control 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.
-- Electric control box
-- Cable remote control
-- Radio remote control system
-- Junction box for proximity switches
A820062_03_0208D
315
3.8.1
Central Module
Control Cabinet
The central module control cabinet is illustrated below. Some of the

control and operating elements illustrated below may not be present on
your machine. The hole will be covered with a blanking plug if a
control or operating element is omitted.
You will find the description of any additional door modules and their
control and operating elements fitted in place of the blanking plates on
the following pages.
5
6
10
11
11
12
11
11
A820062_03_0208D3
1
2
Operating/
control element
Red indicator lamp (optional)
Red indicator lamp (optional)
3
4
5
6
Toggle switch
Toggle switch (optional)
No 0
316
Meaning/Function
Coolant overheating
High--pressure water pump
dry--running cut--out
Hydraulic fluid radiator On -- Off
Coolant overheating Off
Pumping operation -- Service operation
Working light On -- Off
Belongs
with no:
4
A820062_03_0208D
5
6
10
11
11
12
11
11
A820062_03_0208D4
Continued
Operating/
No
control element
7 Toggle switch (optional)
8 Toggle switch (optional)
9 Locally latched toggle switch
10 Multiple display
11 Blanking plate
12 Female connector
A820062_03_0208D
Meaning/Function
Belongs
with no:

Local control -- 0 -- Remote control
Display
Options for door modules
Connection for remote control
317
Multiple Display
2
7
A820062_03_0208D5
No 0
318
Belongs
with no:
Control element
Meaning/Function
1
2
3
4
5
Thermometer
Operating hours meter
Green display
Green display
Red display
6
7
Red display
Green display
Hydraulic fluid temperature display

Operating hours display
Forward pumping On
Reverse pumping On
Hydraulic fluid overheating /
Temperature sensor lead break
Hydraulic fluid radiator fan On
A820062_03_0208D
Special Features of the Control Cabinet

Locally latched
toggle switches
To use a toggle switch that has been latched locally, you must first pull
it out and then push it towards the symbol.
Locking
The control cabinet may be found in a stowage compartment. You must

always lock this stowage compartment to prevent any unauthorized
person switching the control system over.
Switchover from local to

remote control
The EMERGENCY SHUT--DOWN circuit is activated automatically

when you switch over from local to remote control. You must operate
the horn to deactivate the EMERGENCY SHUT--DOWN circuit.
Coolant overheating
The Coolant overheating indicator lamp is connected to the vehicles

warning system. In the event of an engine fault, the machine is
switched to EMERGENCY SHUT--DOWN and the engine is shut
down. Once you have eliminated the fault, you must press the Coolant
overheating Off toggle switch before you can restart the engine. You
can override the shut--down by holding down the Coolant overheating
Off toggle switch in order to operate the machine for a short time (eg
to pump out the hopper and delivery line).
Pumping operation -- Service operation
Use the Pumping operation -- Service operation toggle switch to

switch over between the concrete pump and the compressor. You can
switch on the compressor, rather than the pump, at the remote control if
you set the switch to Compressor.
Note
As soon as the compressor is switched on, the agitator control block is
no longer supplied with hydraulic fluid, ie the agitator and the water
pump will not run.
A820062_03_0208D
319
Hydraulic fluid temperature display in the multiple display
The hydraulic fluid temperature is measured at the main hydraulic

pump. The left--hand green LED flashes if the hydraulic fluid temperature is below approximately 65 _C at this point.
The left--hand LED of the two red LEDs lights up if the hydraulic fluid
temperature exceeds 90 _C. The red Hydraulic fluid overheating display lights up at the same time. The two red LEDs flash alternately if
the hydraulic fluid temperature exceeds approximately 95 _C.
Operating hours display in

the multiple display
The operating hours meter is activated when the pump is switched on.
The flashing egg--timer symbol in the display indicates that the meter is
active.
Status displays in the multiple display
These displays indicate the machines statuses. The two red displays
indicate the following:
-- EMERGENCY SHUT--DOWN activated symbol lights up:
-- Hydraulic fluid overheating symbol lights up: The hydraulic fluid
is too hot. The red LEDs in the temperature display light up or flash
depending on the temperature.
-- Hydraulic fluid overheating symbol flashing: The temperature
sensor on the main hydraulic pump is defective or there is a break in
the cable. The two red LEDs in the temperature display flash alternately and the hydraulic fluid radiator fan begins to run at the same
time (one fan runs where there are two hydraulic fluid radiators).
Caution
In the event of a fault or a line break to the temperature sensor on the
main hydraulic pump, the switch--off temperature (90 _C) for the hydraulic fluid is no longer monitored. This means that the machine will
not be switched off should the hydraulic fluid overheat.
Switch the machine off and replace the temperature sensor if the Hydraulic fluid overheating display flashes.
320
A820062_03_0208D
3.8.2
Control Panel
in the Steps
The control panel is located in or near the steps. The truck mixer driver
can control the most important functions of the pump from the control
panel. In addition, it provides an opportunity for local operation of the
machine. Some of the control and operating elements illustrated below
may not be present on your machine. The hole will be covered with a
blanking plug if a control or operating element is omitted.
8
7
A820062_03_0208D6
1
2
3
4
5
Operating/
control element
Green indicator lamp
Toggle switch
Toggle switch
Momentary--contact switch
Toggle switch
6
7
8
Toggle switch
Toggle switch
Green indicator lamp
No 0
A820062_03_0208D
Meaning/Function
Belongs
with no:
Boom centralized lubrication system

Increase -- Reduce engine speed
Vibrator On -- Off
EMERGENCY SHUT--DOWN
Horn + deactivate EMERGENCY SHUT-DOWN / Pump Off
Forward pumping -- 0 -- Reverse pumping
Centralized lubrication system
Pump centralized lubrication system
321
Special Features of the Control Panel

Restart pump after
EMERGENCY
SHUT--DOWN
If you have pressed the EMERGENCY SHUT--DOWN button, you

may only start the pump up again as described below:
-- unlock the EMERGENCY SHUT--DOWN button by turning it,
-- press the Horn + deactivate EMERGENCY SHUT--DOWN toggle
switch,
-- switch the pump off and then on again using the Forward pumping-0 -- Reverse pumping toggle switch.
Locally latched
toggle switches
Forward pumping -- 0 -Reverse pumping
The function of the Forward pumping -- 0 -- Reverse pumping toggle

switch depends on the switch position of the Local--Remote switch on
the control cabinet.
-- When the toggle switch is set to Local, it has the functions given
above.
-- When the switch is set to Remote, it is only possible to switch the
pump off using the Pump off toggle switch.
Centralized lubrication
system
The centralized lubrication system for this machine is described on the

following pages.
Note
If your machine is equipped with pump centralized lubrication system,
the pump centralized lubrication system and the boom centralized lubrication system are two completely independent systems, that is two
pumps, two lubricant reservoirs, two controllers, etc. The toggle switch
can then be pressed in either direction and it will address the system
selected.
322
A820062_03_0208D
Technical data
Rated voltage
(V DC)
12 / 24
Operating voltage
(V DC)
10 ... 30
Off--load current at 12 V
(mA)
15
Off--load current at 24 V
(mA)
18
Motor current
(A)
Lamp current
(A)
Ambient temperature
(C)
--40 ... +80
Inputs
secure against polarity reversal
Outputs
secure against polarity reversal/

short--circuit protected
Relative operating period

Degree of protection fitted in the
pump casing
A820062_03_0208D
(%)
100
IP 6 K 9 K DIN 40050 T9
323
Indicator lamps
The indicator lamps give you information regarding the function of the
centralized lubrication system or of any faults on it.
Note
When the pump is switched on, the indicator lamp lights up for
approximately 2 seconds and the system is tested. The lubricating motors will run for a fraction of a second. The indicator lamps will go out
after 2 seconds if the system is in order. A flashing indicator lamp indicates one of the conditions described below.
Flash interval
Meaning
2 seconds on, then off
Self--test after pump switched on
1 second on, 1 second off
Fault in the drive motor or supply line
second on, second off
Lubricant reservoir empty
second on, 1 second off
Fault in the lubrication circuit

Lubrication in progress
Steady light
324
A fault which was previously indicated has been

acknowledged (see toggle switch)
A820062_03_0208D
Programming
Various settings are programmed into the centralized lubrication system in the works. These settings regulate the lubrication intervals and
the lubrication time. Have the default settings modified by the After
Sales Department if either the lubrication intervals or the lubrication
times do not meet your needs. The following settings are stored:
Interval time
The interval time is the time between two lubrication procedures.

The interval time only runs down when the ignition is switched on. The
interval times are retained during interruptions. The new times are
added on restarting.
Working time
The working time is the time for which the centralized lubrication
pump operates for one lubrication procedure. The working time is the
period during which a response must be received from the piston detectors.
Monitoring time
The monitoring time starts when the centralized lubrication pump

is switched on. The monitoring time is the time taken for the piston
detector to respond.
A820062_03_0208D
325
3.8.3
Cable Remote
Control
The standard cable remote control for this machine is illustrated below.
1
10
2
11
3
7
6
1
2
Operating/
control element
Joystick
Rotary controller
3
4
Toggle switch
Toggle switch
5
6
Rotary controller
Toggle switch
7
8
9
10
Toggle switch
Toggle switch
Locally latched toggle
switch
Red indicator lamp
11
Momentary--contact switch
No 0
326
A820062_03_0208D7
Belongs
with no:
Meaning/Function
Boom control
Setting the boom speed if no 6 is switched to
the Snail switch position
Horn + deactivate EMERGENCY SHUT-DOWN /
Change--over
Increase -- Reduce output
Boom speed preselection:
Hare = 100%
Snail = 0 -- 100%
Engine On -- Off
Boom functions -- 0 -Support leg control
Fault (eg EMERGENCY SHUT--DOWN
operated)
EMERGENCY SHUT--DOWN
A820062_03_0208D
Special features of the cable remote control

Restart pump after
EMERGENCY
SHUT--DOWN
The red Fault indicator lamp lights up when the EMERGENCY

SHUT--DOWN button is pressed. You may only start the pump up
again as described below:
-- unlock the EMERGENCY SHUT--DOWN button by turning it,
-- press the Horn + deactivate EMERGENCY SHUT--DOWN toggle
switch,
-- switch the pump off and then on again using the Forward
pumping -- 0 -- Reverse pumping toggle switch.
Locally latched
toggle switches
A820062_03_0208D
327
3.8.4
Radio Remote
Control
The transmitter for a proportional radio remote control is described

below.
11
10
12
13
4
7
6
1
2
3
4
Operating/
control element
Joystick
Toggle switch
Toggle switch
Toggle switch
5
6
Rotary controller
Locally latched toggle switch
No 0
328
Meaning/Function
Boom control
Radio remote control unit On -- Off
Horn + deactivate EMERGENCY SHUT-DOWN / Change--over
Increase -- Reduce output
Preselect boom speed:
Snail = 50% of the works setting -User--defined speed -Hare = 100% of the works setting
A820062_03_0208D8
Belongs
with no:
12
10
A820062_03_0208D
11
10
12
13
4
7
6
Continued
Operating/
No
control element
7 Toggle switch
8 Toggle switch
9 Locally latched toggle switch
10 Toggle switch
11 Momentary--contact switch
12 Green indicator lamp
13
Red indicator lamp
A820062_03_0208D
Meaning/Function
Engine On -- Off
Boom functions -- 0 -- Support leg control
Program user--defined boom speed
STOP function
Flashing: remote control unit in service
Off: no contact with receiver
Flashing: battery flat
A820062_03_0208D9
Belongs
with no:
7
2
329
Receiver
1
2
3
6
A820062_03_0208D10
No 0
1
2
3
4
5
6
330
Operating/
control element
Female connector
Antenna with base
Battery compartment
Indicator lamps
Red indicator lamp
Female connector
Meaning/Function
Belongs
with no:
Antenna connection
Control signal reception
Charge battery
Operating states display
Battery charge state
Connection to the control cabinet
A820062_03_0208D
Special features of the radio remote control

STOP button
Putzmeister radio remote controls include a STOP button having the

same function as the EMERGENCY SHUT--DOWN buttons on the
machine. This is a requirement of European standard EN 60204--1.
Restart pump after STOP
You may only start the pump up again as described below if you have
pressed the STOP button:
-- unlock the STOP button by turning it,
-- switch remote control unit off and back on again,
-- press the Horn + deactivate EMERGENCY SHUT--DOWN
toggle switch,
-- switch the pump off and then on again using the Forward pumping
-- 0 -- Reverse pumping toggle switch.
Frequency change
12 frequencies on the frequency band have been assigned to this radio

remote control. As soon as you switch the transmitter off or press the
STOP button on the transmitter, the link between the transmitter and
receiver is broken. The radio remote control automatically advances to
the next frequency when you switch the transmitter back on.
Additional antennae
You must maintain a minimum clearance of 1 m between the radio remote control antenna and any additional antennae (eg radio, telephone)
you fit, as otherwise these may interfere with the radio remote control.
Locally latched
toggle switches
Joystick
The two joysticks can be used to control the individual boom functions.
You can control some of the boom functions for 4 and 5 arm booms by
rotating the joysticks.
A820062_03_0208D
331
Preselect boom speed

toggle switch
You can select different speeds of movement for the boom using the
Preselect boom speed toggle switch.
-- In the Snail position of the switch, the boom functions are operated
at 50% of the speed set in the works.
-- In the middle position of the switch, the boom functions are operated
at the user--defined speeds of movement.
-- In the Hare position of the switch, the boom functions are operated
at 100% of the speed set in the works.
Program user--defined
boom speed toggle switch
You can program your own speed for each of the boom functions using
the Program user--defined boom speed toggle switch.
-- You program the maximum boom speeds with the toggle switch
in the upper position.
-- You program the minimum boom speeds with the toggle switch
in the lower position.
Programming your own

boom speed
Each boom movement must be programmed individually.

Programming a maximum speed
332
"
Set the Preselect boom speed toggle switch to User--defined

speed.
"
Press the Program user--defined boom speed toggle switch up

and hold.
"
Use the joystick to control the boom movement desired at the

speed that is to become the maximum speed for full joystick
deflection.
"
Release the toggle switch first and then the joystick.
A820062_03_0208D
Programming a minimum speed

"
Set the Preselect boom speed toggle switch to User--defined

speed.
"
Press the Program user--defined boom speed toggle switch

down and hold.
"
Use the joystick to control the boom movement desired at the

speed that is to become the minimum speed for minimum joystick deflection.
"
Release the toggle switch first and then the joystick.
Now when you set the Preselect boom speed toggle switch to the
middle position and move the joystick to its full deflection, the boom
movement will be executed at the maximum speed of movement you
have just programmed. When you now move the joystick only slightly,
the boom movement will be executed at the minimum speed of movement you have just programmed.
Note
The electronics in the radio remote control prevent you programming a
minimum speed that is higher than the maximum speed.
Inhibiting individual arm

movements
A820062_03_0208D
If you move the joystick only very slightly so that the boom does not
move when you are programming the maximum speed for a boom
movement, this direction of movement will be inhibited.
333
3.8.5
EMERGENCY
SHUT- DOWN Button
There are a number of EMERGENCY SHUT--DOWN buttons on the

machine. These are located:
-- by every outrigger control block
-- on the cable and radio remote control boxes
-- on the electric control box or near the hopper
Some possible positions of the EMERGENCY SHUT--DOWN button
are shown in the illustration below.
Caution
Familiarize yourself with the locations of the EMERGENCY
SHUT--DOWN buttons on your machine before operating the unit.
30505901
EMERGENCY SHUT--DOWN button
Note
You need only press one of the EMERGENCY SHUT--DOWN buttons to
trigger an EMERGENCY SHUT--DOWN of the machine.
To release the EMERGENCY SHUT--DOWN condition again, you must
unlock the EMERGENCY SHUT--DOWN button that has been pressed
by turning it and sound the horn.
You must switch the pump off and back on again to restart the pump.
All EMERGENCY SHUT-DOWN buttons must be released for machine
operation.
334
A820062_03_0208D
The following actions are triggered in the truck, pump and boom systems when you press one of the
EMERGENCY SHUT--DOWN buttons:
System
Action
Truck
-- Engine speed drops to idle.

-- It is no longer possible to set the engine speed electrically.
-- The EMERGENCY SHUT--DOWN operated indicator lamp lights on the control
cabinet.
-- Variable main pumps go to neutral, the delivery pistons come to a halt, and the Pump
On light flashes.
-- The change--over valve is de-energized.
Pump
Danger
The accumulator pump continues to generate hydraulic flow, which is directed back to
tank instead of operating the function (i.e., the accumulator ceases to be filled).
Boom
-- The boom control unit is disconnected.

-- If the E-stop on the radio transmitter was pressed, the supply voltage to the radio
transmitter is switched off and the power indicator lamp on the radio transmitter goes
out. If an E-stop on the truck was pressed, the power indicator lamp on the radio
transmitter flashes.
-- On the cable remote control system, the supply voltage is switched off with the
exception of that for the horn, the Fault indicator lamp on the cable remote control
unit lights, the Pump on light flashes.
-- The boom pump transports hydraulic fluid in depressurized circulation
(maximum 15 bar) through the boom control unit inlet module to the tank. Emergency
operation of the boom functions is ensured by simultaneous manual operation of the
operating mode selector valve and the corresponding boom arm valve.
Danger
The machine is only switched off electrically when the EMERGENCY
SHUT--DOWN button is pressed. Although this causes all the
electrically actuated hydraulic valves to be switched off, an
uncontrolled sinking of the boom caused by leakages in the hydraulic
system, for instance, cannot be prevented in this way.
A820062_03_0208D
335
3.8.6
Proximity Switch
Junction Box
The junction box for the proximity switches is located next to the
compact block on the right side (seen in the direction of travel) of the
truck.
20500404
Assignment of Proximity Switches to LEDs
Junction Box LEDs
336
There are four proximity switches located on the right drive cylinder of
the core pump, two at the front and two at the rear. These switches
trigger the switchover procedure when the hydraulic pistons approach
the proximity switches. The LEDs for the two proximity switches that
have just been triggered light up on the junction box at the same time.
LED
Proximity Switch
rear (rod side) left
rear (rod side) right
forward (base side) left
forward (base side) right
A820062_03_0208D
Significance of
the Junction Box LEDs
Junction Box LED
Proximity Switch Status
Lights up briefly on switchover
Proximity switch is in order
Does not light up on switchover
Proximity switch, connector or

lead are defective, replace at the
earliest opportunity
Lights up continuously
Proximity switch, connector or

lead are defective, disconnect the
switch (otherwise switchover is
not possible) and replace at
Note
Further LEDs are located on the Proximity switch connector (see page
338). These LEDs indicate whether it is the Proximity switch or the
connector and lead that is defective.
Redundant system
A820062_03_0208D
One of the two proximity switches on each end is sufficient to trigger

the switchover procedure. The second proximity switch serves as a
backup in case one of the two proximity switches should fail. You may
use one of the proximity switches from the other end as a replacement
if both the switches on one end (rod end or base end) fail during a job.
337
3.8.7
Proximity Switch
Connector
The connector for the proximity switch has one yellow and one green
light--emitting diode (LED). These LEDs indicate the status of the
connector and the proximity switch.
Proximity Switch Connector

1
2
3
4
Yellow LED -- Indicates the status of the proximity switch.

Green LED -- Indicates the status of the connector and the lead.
Connector
Proximity Switch
Significance of
Yellow LED
Proximity Switch Status
the Proximity Switch
LEDs
Lights up briefly on switchover Proximity switch is in order
338
Does not light up on switchover
Proximity switch is defective, replace at

Lights up continuously
Proximity switch is defective, disconnect the

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)
A820062_03_0208D
3.8.8
Hopper Grate Cutout

Device
The hopper grate cutout device consists of a switching cam and a

pressure roller switch. The switching cam is fastened to the hinge pin
of the hopper grate, the pressure roller switch to the hopper. The
pressure roller switch is acted on as soon as you open the hopper grate.
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 re--start it.
1
Hopper Grate Cutout Device

1
2
3
4
Hopper
Hopper grate hinge pin
Switching cam
Pressure roller switch
Danger
The pressure roller switch must always be clean and free to move. In
addition, the pressure roller switch must always be in contact with the
switching cam. If the pressure roller switch is defective, the hopper
grate cutout device may not function, or the agitator and the transfer
tube may come to a halt during pumping operations.
A820062_03_0208D
339
Warning
BEFORE LIFTING HOPPER GRATE TO WORK ON CONCRETE PUMP, VERIFY THAT
HOPPER GRATE CUTOUT DEVICE IS WORKING PROPERLY BY PERFORMING THE
FOLLOWING STEPS: (1) While concrete pump is ON, reach hand beneath cutout cover and
push switch up (refer to diagram below). DO NOT ATTEMPT TO RAISE HOPPER GRATE.
(2) Verify that concrete pump turns OFF.
Hopper grate cutout cover,

which is located on
passengers side of truck.
Position of hopper grate cutout

switch with hopper grate
CLOSED. In this position, the
concrete pump can be turned ON.
Position of hopper grate cutout switch

when hopper grate is OPEN. In this
position, the concrete pump should
automatically turn OFF.
340
A820062_03_0208D
3.8.9
Agitator Shut- Off

Valve
The agitator shut--off valve is incorporated into the agitator control

block. If there is no power to the agitator shut--off valve (when the
hopper is open or the EMERGENCY SHUT--DOWN button has been
pressed), hydraulic fluid does not flow to the agitator valve (i.e., the
agitator halts).
1
Agitator Control Valve
1
A820062_03_0208D
Agitator shut-off valve
341
3.9
Hydraulic Control
Devices
The hydraulic control devices and operating elements on this 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.
-- Outriggers control block
-- Boom functions control block
-- Emergency hydraulic ports
-- Agitator lever
-- Water pump lever
-- Compact block valves (e.g., manual volume control valve,
accumulator dump valve, etc.)
-- Transfer tube damping cock
Note
Further control devices and components are described in the
Electrical Control Devices section on page 315 and the
Other Components section on page 350.
342
A820062_03_0208D
3.9.1
Outriggers Control
Block
The outriggers control block on the left--hand side of the truck (drivers
side) is illustrated below. The outriggers control block on the
right--hand side of the truck (passenger side) is a mirror image of this
one.
6
1
22104901
Outriggers Control Block (Located on Drivers Side)

1
2
3
4
5
6
Left outrigger on/off lever -- Push lever in and hold to activate the left
outrigger controls or release lever to deactivate the left outrigger controls.
Outrigger left front (LF) up/down -- Pull lever out to raise LF outrigger or
push in to lower LF outrigger.
Outrigger left rear (LR) up/down -- Pull lever out to raise LR outrigger or
push in to lower LR outrigger.
Outrigger left front (LF) out/in -- Pull lever out to extend LF outrigger or
push in to retract LF outrigger.
Outrigger left rear (LR) out/in -- Pull lever out to extend LR outrigger or
push in to retract LR outrigger.
EMERGENCY SHUT-DOWN button
Note
The support control block is designed as a two--hand control device
(i.e. to execute a function, you must operate the on/off lever and the
corresponding function lever simultaneously).
The hydraulic outrigger valves are spring--loaded (i.e., the valves are
automatically reset to the 0 position when you release the lever).
A820062_03_0208D
343
3.9.2
Boom Functions
Control Block
The control block can be operated manually and thus provides security
of operation if a functional fault occurs in the remote control system.
Boom Functions Control Block (Located on Passengers Side of Truck)

1
2
3
4
5
6
344
D Arm -- Pull out to raise D arm or push in to lower D arm.

C Arm -- Pull out to raise C arm or push in to lower C arm.
B Arm -- Pull out to raise B arm or push in to lower B arm.
A Arm -- Pull out to raise A arm or push in to lower A arm.
Slew -- Pull lever out to slew boom clockwise or push in to slew boom
counter-clockwise.
Operating mode selector valve (OMV) -- Push to engage boom functions or
pull to engage outriggers.
A820062_03_0208D
3.9.3
Agitator Lever
The agitator control block with the agitator lever is mounted on the
right front corner of the hopper. Use the agitator lever to switch on the
agitator in either direction of rotation.
1
2
3
Operation of Agitator Lever

1
2
3
4
Agitator ON (lever upwards) -- Agitator direction away from the delivery

cylinder
Agitator OFF
Agitator ON (lever downwards) -- Agitator direction towards the delivery
cylinder
Water lever
Note
As the two valves on the agitator control block are supplied by a single
hydraulic pump, it may be the case that the volume of hydraulic fluid is
not adequate to supply the functions of both valves with sufficient
hydraulic fluid at the same time. It can therefore be the case that the
agitator does not operate when the water pump is switched on, or that
the water pump does not operate when the agitator is switched on.
A820062_03_0208D
345
3.9.4
Water Pump Lever
The water pump lever is located next to the agitator lever on the
agitator control block.
Operation of Water pump lever

1
2
3
Water pump ON
Water pump OFF
Agitator lever
Note
As the two valves on the agitator control block are supplied by a single
hydraulic pump, it may be the case that the volume of hydraulic fluid is
not adequate to supply the functions of both valves with sufficient
hydraulic fluid at the same time. It can therefore be the case that the
agitator does not operate when the water pump is switched on, or that
the water pump does not operate when the agitator is switched on.
346
A820062_03_0208D
3.9.5
Accumulator Dump
Valve, Accumulator
Dump Cock, Transfer
Tube Damping Cock
This machine is fitted with an electrical agitator safety cutout. The

accumulator pressure is dumped through an accumulator dump valve
and the transfer tube halts, among other measures, as soon as the grill
on the hopper is opened. The accumulator dump valve is located on the
left of the hydraulic block, seen in the direction of travel.
The machine is fitted with an additional accumulator dump cock. The
accumulator pressure is also dumped when the accumulator dump cock
is opened. The transfer tube will still switch over while the machine is
running, although at a lower pressure and very slowly. This will allow
you to halt the transfer tube in the center position by switching off the
machine at the appropriate moment. You can then check the wear ring
using a mirror, for example.
The transfer tube damping cock is incorporated in the hydraulic fluid
supply line to the accumulator.
Danger
The transfer tube will continue to switch over when the accumulator
dump cock has been opened and the machine is running. There is still a
danger of crushing and severing of limbs.
Never reach into the hopper from below through the wash--out port nor
from above through the grill while the machine is running. Never poke
anything into the hopper.
A820062_03_0208D
347
A820062_03_0208D11
No 0
1
2
3
4
5
348
Designation
Accumulator
Additional accumulator dump cock
Accumulator pressure gauge
Accumulator dump valve
Transfer tube damping cock
A820062_03_0208D
3.9.6
Manual Volume
Control
On this machine, the output is adjusted by means of a proportional

valve. This proportional valve is integrated in the Free--Flow
Hydraulics control block. The handwheel required for emergency
operation is located on the forward end of the Free--Flow Hydraulics
control block on the right viewed in the direction of travel.
No 0
1
Designation
Emergency operation handwheel
Note
The proportional valve must be fully open during normal operation,
i.e. the emergency operation handwheel must be turned fully
counterclockwise (opened).
A fixed value of 75% is set on the proportional valve when you switch
over from remote control to local control on the control cabinet, and
the output can only be controlled by the engine speed. This means
that an output of 75% of the maximum output is possible at maximum
engine speed.
In emergency operation you are able to set the output desired on the
proportional valve using the handwheel. The further you turn the handwheel clockwise, i.e. the further you close the proportional valve, the
greater the output will be.
A820062_03_0208D
349
3.10
Other Components
The other components of this machine are described on the following

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.
-- Flushing water pump
-- End hose
-- Vibrator
-- Hydraulic fluid radiator
-- High-pressure water pump
Note
Further control devices and components are described in the
Hydraulic Control Devices section on page 342 and the
Electrical Control Devices section on page 315.
3.10.1 Flushing Water Pump
The flushing water pump generates a maximum water pressure of 368

psi (25 bar) and a maximum water delivery rate of 42 gallons per
minute (160 liters per minute).
Flushing Water Pump (Located on Top of Water Tank)

1
2
3
350
Water hose connection

Hydraulic motor
Flushing Water pump
A820062_03_0208D
3.10.2 End hose
The machine is fitted with a 3 or 4 m long end hose depending on the

model. The maximum permitted end hose length is shown on the boom
rating plate. The push--in tubes for the end hose catch brackets are
indicated by a plate on the last arm for the end hose length specified.
2
1
3
22500301
End Hose
1
2
3
Push-in tube for 3 meter end hose

Push-in tube for 4 meter end hose
Plate indicating length of end hose
Danger
It is forbidden, under normal conditions of use, to extend the end hose
or to fit an end hose longer than that specified on the rating plate. The
machine can tip over if you use a longer end hose.
A820062_03_0208D
351
Note
End hoses may not be fitted with any extension coupling, outlet shoes
or other dangerous outlet fitting. However, you can use the modified
Putzmeister end hose with a flow restrictor if you wish to achieve a
uniform flow of concrete for filling hollow blocks.
1
2
32500601
Modified Putzmeister End Hose With a Flow Restrictor

1
2
3
4
Rubber protective sleeve

Modified end hose
Push-in spout
Flow restrictor
Danger
The modified end hose with a flow restrictor may only be used for
filling hollow blocks. The rubber protective sleeve must always be
pulled fully down over the push--in spout, whether or not you are using
the flow restrictor. The end hose may no longer be used if the
protective sleeve is damaged or missing.
352
A820062_03_0208D
Note
The end hose is permanently exposed to high loads and severe wear. It
is, therefore, possible that a heavily worn end hose may tear at the
push--on connection. The retaining rope prevents the end hose from
falling.
Retaining Rope on the End Hose

1
2
3
4
Snap hook
Retaining rope
Push-on connection
Hose clamp
Danger
The retaining rope prevents the end hose falling if it tears away or if
the coupling is opened. The end hose must therefore always be secured
by a retaining rope.
The retaining rope must be passed around one of the clamping bolts on
the hose clamp and secured to the boom by the snap hook. Fastening
the retaining rope to the coupling is prohibited as otherwise the end
hose would fall when the coupling was opened.
Check the retaining rope for damage every day. A damaged retaining
rope must be replaced by a new retaining rope immediately.
A820062_03_0208D
353
3.10.3 Vibrator
The vibrator is bolted to the grill. It causes the grill to vibrate and thus
prevents bridges forming on the grill, particularly in the case of very
stiff concrete. The vibrator is electrically driven and its connector must
be plugged into the appropriate round socket on the side of the electric
control cabinet. The vibrator is switched on and off either at the
electric control cabinet or on the control panel by the steps.
2
1
3
4
Vibrator
1
2
3
4
354
Grill
Vibrator
Supply cable
Plug
A820062_03_0208D
3.10.4 Hydraulic Fluid

Radiator
The machine is fitted with two hydraulic fluid radiators. Each radiator
has its own fan. Some of the hydraulic fluid in the machine first flows
through these radiators before returning to the reservoir. The fans on
these radiators switch on once the hydraulic fluid reaches a temperature
of 131 _F (55 _C) at the main hydraulic pump.
Hydraulic Fluid Radiator

1
2
3
4
A820062_03_0208D
Control cabinet symbol for the hydraulic fluid radiator

Hydraulic fluid return circuit
Fan
Hydraulic fluid supply circuit
355
Note
You may switch on both fans at any time using the toggle switch on the
control cabinet, whatever the fluid temperature, should you wish to
cool the hydraulic fluid as a precautionary measure before it has
reached 131 _F (55 _C). The green indicator lamp on the control
cabinet will light up as soon as a temperature of 131 _F (55 _C) is
reached, or if you have switched on the fans.
Leave the truck engine running during breaks in pumping or when
pumping is completed until the fan motors switch themselves off.
The hydraulic fluid is also cooled by the water in the water box. The
hydraulic fluid warms up the piston rods for the drive cylinders. These
are flushed, and thus cooled, by the water in the water box on each
stroke movement. This also cools the hydraulic fluid. The water in the
waterbox should be flushed and refilled daily.
356
A820062_03_0208D
Travel
This topic:
A820062_04_0208D
Starts on page:
4.1 Driving
42
4.2 Towing
44
4.3 Loading
48
41
Travel
4.1
Driving
The truck-mounted concrete pump may be driven on public highways

only if the vehicle and driver are properly licensed.
4.1.1
Prior to Driving
Prior to driving the truck, perform the following actions:

Check that the vehicle is safe to drive (lighting, brakes, tire
pressures, etc.).
Verify that the following items stored on the truck are properly
secured:
-- Delivery hoses
-- Delivery pipes
-- Clamps
-- Tools
-- Outrigger pads
-- Cable remote control box and cable
Verify that the outrigger legs are secured in the transport position.
Danger
To prevent the outriggers from accidentally extending while the truck is
moving, close the hydraulic shut--off valves in the outrigger system and
ensure that each outrigger leg snaplock is secured by a spring pin.
Ensure that the truck maximum allowable weight limits are not
4.1.2
42
Driving in Reverse
exceeded. Also ensure that all local or state weight limits are not
exceeded.
Check that the oil and water reservoirs are securely closed and not
leaking.
Verify that PTO switch in truck cab is in DRIVE position. If not,
depress clutch pedal, start engine, and flip PTO switch to DRIVE
position.
Do not drive the unit with concrete in the hopper.
Remove all concrete delivery line components from the pump.
Verify that the boom is in its stowed position (i.e., not unfolded).
If you have to drive in reverse, perform the following actions:

Always ask for a marshaller to guide you.
Agree upon clear hand signals with the marshaller before backing
up.
If necessary, have the route blocked or secured by assistants.
Have the site management arrange for the removal of any materials
or equipment that hinder your approach.
Ensure that pusher axle is in raised position.
A820062_04_0208D
Travel
4.1.3
During the Journey
Due to the size and weight of the truck, observe the following
precautions 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 height of the truck in height restricted areas (i.e.,
underpasses, under bridges, etc.).
Be aware of the elevated position of the trucks center of gravity
when travelling on a slope and on ascending or descending routes.
Danger
The truck may never be driven with the placing boom unfolded. This
may cause the truck to tip over.
12000100
Never drive the truck with the boom unfolded.
A820062_04_0208D
43
Travel
4.2
Towing
The truck-mounted concrete pump may only be towed in accordance

with the truck manufacturers rules. Use the towing equipment
provided. As shown in the diagram below, a coupling is fitted on the
front of the truck for breakdown rescue or towing the truck:
Caution
Only use the towing eye on the rear of the truck for assistance on the
construction site if a tow-bar cannot be fitted to the front of the truck.
Never tow the truck by the pump unit or the hopper.
Tow coupling on the front of the truck
44
A820062_04_0208D
Travel
40000204
Caution
If you wish to tow the machine from the towing eye on the rear swinging support leg, the swinging support leg must be swung fully in, and
the direction of towing must be along the truck axis. Serious damage
may be caused to the boom pedestal, the swinging support leg and the
slewing cylinder if the swinging support leg is swung out, or if you tow
at an angle.
Make sure that the towing rope or the tow--bar does not damage the
hopper or other parts of the bodywork if you use the towing eye near
the hopper.
A820062_04_0208D
45
Travel
10000400
Towing eye on the rear of the truck
You must use the towing eye on the rear of the truck to tow the truck
from the rear.
40000203
Towing eye
The towing eye on machines with TRS 60 or TRS 70 boom pedestals is

mounted over the compartment housing the rear support.
46
A820062_04_0208D
Travel
40000201
Towing eye on the support cylinder
The lifting eye on the support cylinder may be used as the towing eye
on M 42 and larger machines.
40000202
Towing eye at the rear of the swinging support leg
The towing eye on machines with TRDI 60 or TRDI 70 boom

pedestals is mounted on the rear of the swinging support leg.
A820062_04_0208D
47
Travel
4.3
Loading
The standard slinging hooks fitted to the machine are there for
assembly purposes only. Slinging hooks suitable for lifting the
complete machine can be ordered on a new machine and may, possibly,
be retro--fitted to an old machine. If your machine is fitted with
suitable slinging hooks, they will be identified as follows:
10002400
Plate for slinging hooks
Suspended load
Raised loads may fall if they are not loaded properly or if the slings
and hooks are damaged.
You should, therefore, never walk under suspended loads.
Caution
The machine may only be loaded by crane if it is equipped with
suitable slinging hooks. Lifting equipment, lifting tackle, supports and
other auxiliary equipment shall be safe in use and operation. Make
sure that the loadbearing capacity is adequate.
10000600
Do not lift the machine by the assembly slinging points
48
A820062_04_0208D
Operation
This topic:
A820062_05_0208D
Starts on page:
5.1 Preliminary Information
52
5.2 Function Checks
53
5.3 Setup
57
5.4 Boom Movements
527
5.5 Hand Signals for Boom and Pumping Operations
533
5.6 Extending the 36Z 4-Section Boom
534
5.7 Pumping Operations
540
5.8 Cleaning
550
5.9 Teardown
565
5.10 Pumping Concrete with the Emergency Stroke Kit
572
51
Operation
5.1
Preliminary
Information
Before attempting to place material with the truck-mounted concrete

pump, operators must be thoroughly trained in its operation. Before
using the truck-mounted concrete pump, complete the following steps:
Perform routine truck maintenance as outlined in your truck owners
manual.
Completely inspect the truck-mounted concrete pump for worn or
damaged parts, loose bolts, missing parts, etc.
Perform periodic maintenance on the truck-mounted concrete pump,
as outlined in the Maintenance section of this manual.
Warning
Read and comply with all safety rules, notes, and warnings contained
in this manual. This is absolutely essential to the safe, efficient
operation of the truck-mounted concrete pump.
Note
Prior to starting up the machine, you should become so familiar with
the machine that damage and accidents cannot occur. Every time you
use the machine, you accept full responsibility for the safety of anyone
located in the machines danger zone. You are therefore under an
obligation to ensure that the machine is completely safe in operation.
52
A820062_05_0208D
Operation
5.2
Function Checks
You should check the following functions before you begin using the
machine on the construction site
5.2.1
Pump Functions
The basic precondition for problem--free operation of the machine is a

properly functioning pump.
Switchover
Check for the proper switchover function of the delivery pistons and
the transfer tube at various speeds of the drive motor and settings of the
flow regulator.
Proximity Switch
20500405
Check the Proximity Switch
Check whether the drive cylinders are switching over automatically as

soon as the pistons of drive cylinder I (on the right in the direction of
travel) approach the two forward or rear proximity switches. The
associated indicator lamp on the distributor casing should light up
briefly. If one of the indicator lamps does not light up, the associated
proximity switch is defective.
Stroke Length
Press the switchover button on the remote control at a slow delivery

piston speed and hold it down.
The delivery pistons should 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
Fully close manual volume control valve (by rotating

counterclockwise) to have pump operate at maximum speed. Measure
the stroke time over ten individual strokes. The value determined,
divided by 10, must comply with the ratings on the Pump test reading
sheet following the machine card in the Technical Data section.
A820062_05_0208D
53
Operation
5.2.2
Filter Functions
Dirty filters reduce the fluid flow considerably so that damage may
occur in the hydraulic system.
Vacuum Filter
10300200
Vacuum Meter -- The filter element must be replaced if the vacuum meter indicator
is in the red zone at more than 85F (30C) fluid temperature and the fastest
stroke time.
Boom Filter
Pressing Down the Red Button on the Boom Filter
1. Warm the hydraulic fluid up to normal operating temperature (>

120F (50C)).
2. Set the maximum pumping rate.
3. Press in the red button on the boom filter if it is sticking out.
Note
You must replace the boom filter element if the red button pops out
again after a short time.
The boom filter is OK if the red button remains depressed.
Comply with the waste disposal regulations in force for your area when
changing the fluid filters.
54
A820062_05_0208D
Operation
5.2.3
EMERGENCY
SHUT- DOWN
Function
It is only possible to intervene rapidly in the event of danger if all the

EMERGENCY SHUT--DOWN buttons are functioning.
Caution
The machine is no longer safe in operation if the EMERGENCY
SHUT--DOWN button is defective, as you will no longer be able to
switch the machine off quickly enough if danger threatens.
You must therefore inspect the function of the EMERGENCY
SHUT--DOWN buttons and the lever position for the boom valves (see
Function check on the boom control unit) before starting work each
time.
Danger
The machine is only switched off electrically when the EMERGENCY
SHUT--DOWN button is pressed. Although this causes all the
electrically actuated hydraulic valves to be switched off, an
uncontrolled sinking of the boom caused by leakages in the hydraulic
system, for instance, cannot be prevented in this way.
Furthermore, the EMERGENCY SHUT--DOWN circuit has no
influence on the agitator pump (i.e., the agitator continues to rotate,
despite the EMERGENCY SHUT--DOWN button having been pressed
in).
A820062_05_0208D
55
Operation
EMERGENCY
SHUT- DOWN Button
10500200
Press -- Lock EMERGENCY SHUT--DOWN

Turn -- Unlock EMERGENCY SHUT--DOWN
1. Switch the pump on.

2. Operate a boom function.
3. Press one of the EMERGENCY SHUT--DOWN buttons.
The pump and the boom must come to a halt immediately.
4. Check all EMERGENCY SHUT--DOWN buttons on the machine
and on the remote control in the same way.
5.2.4
Function Check on
the Boom Control
Unit
You may only operate the machine if the boom control unit is fully
functional.
1. Switch on the radio or cable control.
2. Operate the boom control levers briefly several times while
observing the levers on the boom control unit. The lever for the
boom valve operated and the lever for the operating mode selector
valve must move each time.
Note
As soon as you release the boom control levers on the remote control
unit, the levers for the boom arm valves previously actuated and for the
operating mode selector valve must return to the central position (zero
position).
The reactions of the operating mode selector valve on the boom control
unit are delayed by approximately 0.8 seconds if you use the cable
control or radio.
56
A820062_05_0208D
Operation
5.3
Setup
5.3.1
Pre-Operation
Inspection
Prior to operating the truck-mounted concrete pump, perform a

pre-operation inspection by checking the following items:
Note
Performing a pre-operation inspection prevents downtime and helps
maintain the truck-mounted concrete pump in proper working
condition between scheduled maintenance checks.
Warning
Defective components, structural damage, missing parts or equipment
malfunctions, jeopardize the safety of the operator and other personnel
and can cause extensive damage to the machine. A poorly maintained
machine could become the greatest operational hazard you may
encounter. It should be a common practice that the operator perform a
thorough walk-around inspection before each days operation of the
concrete pump.
Note
All water, oil, and fuel levels should be checked and topped off as
necessary. The machine must be level when you check the functional
fluids. The boom and the supports must be retracted. The water box on
concrete pumps must be full during operation, even if there is a risk of
freezing.
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
manufacturers information.
Danger
If any discrepancy is noted during the pre-inspection, attach a sign at
the control panel stating DO NOT OPERATE and repair the
discrepancy before operating the truck-mounted concrete pump.
A820062_05_0208D
57
Operation
Overall machine condition:
58
-- External structural damage

-- Wheel lug nuts (missing or loose)
-- Wiring and brake lines
-- Condition of tires (tears, cracks or cuts, inflation)
-- Missing decals, placards, warning signs
-- Missing, broken or damaged parts, bolts and nuts
-- Control panel, switches, gauges, volume control
-- Electrical system for frayed or broken wires or loose connections
Engine
-- Fuel level
-- Oil level
-- Mounting (bolts, wiring, hoses)
-- Fuel or oil leaks
-- Belts (fan, alternator)
Battery
-- Battery condition
-- Cables and connections (ground connection)
-- Battery hold down security
Hydraulic System
-- Hydraulic leaks
-- Loose or damaged hoses, tubing
-- Fluid level, hydraulic tank breather cap. Refill only with an
appropriate hydraulic fluid listed in the Recommended
Lubricants section on page NO TAG.
-- Hydraulic valves and control levers
-- Cleanliness of hydraulic fluid. Non-milky, bright in color
-- Hydraulic cylinders, S--tube shift and delivery cylinders
Hopper
-- Grate in place, not damaged
-- S--tube
-- Remixer agitator, drive motors (if equipped)
-- Outlet cleanliness
-- Lubrication
Boom
-- Lubrication
-- Missing, broken or damaged parts, bolts and nuts
-- Hydraulic leaks
-- Loose or damaged hoses, tubing
A820062_05_0208D
Operation
5.3.2
Preliminary Setup
Prior to setting up the truck-mounted concrete pump, perform the

following steps:
Note
As a rule, the site management determines the setup site for the
machine and prepares the site accordingly. However, the machine
operator is responsible for setting up the machine safely. The machine
should only be set up on level ground. Inspect the proposed site
carefully and reject the setup site if you have any doubts about the
safety of the site.
1. Walk the approach route before you drive it. Ask for someone to
give you directions if you have to drive the truck in reverse.
2. Maintain a safe distance from pits, slopes, trenches, etc., when
approaching the setup site and when setting up. Check the
condition of the soil or flooring where the machine will be
positioned. As shown in the diagram below, the force transferred
into the ground by each outrigger is distributed through the ground
in a conical pattern at a 45 angle. This imaginary cone must not
exit through the wall of the pit. Ensure that you maintain a safe
distance from any pits (i.e., at least a), as mentioned below:
A. If the ground has a good loadbearing capacity, maintain a
minimum clearance of a from a pit even if the pit is shallow.
The minimum clearance a from a pit for machines
up to 26,000 lbs permissible gross weight, is 3.3 feet (1 m);
over 26,000 lbs permissible gross weight, is 6.6 feet (2 m)
A820062_05_0208D
59
Operation
45
Minimum Clearance a From a Pit
B. If the ground does not have a good loadbearing capacity,

maintain an additional safety clearance A from a pit. As
shown in the diagram below, the additional safety clearance
A from a pit:
for loose, backfilled ground is equal to twice the pit depth
(i.e., A 2 pit depth T),
for compact, solid ground is equal to the pit depth
(i.e., A 1 pit depth T).
510
A820062_05_0208D
Operation
A2T
A1T
A
T
12100402
Additional Safety Clearance A From a Pit
Calculation Example 1
Permissable gross weight of machine = 45,000 lbs

(Therefore the minimum distance from the pit a = 6.6 feet)
Type of ground = loose, backfilled; depth of pit (T) = 3 feet
(Therefore the additional safety clearance from the pit A = 2 x 3 ft = 6 ft)
Required distance from pit (i.e., greater of a (6.6 ft) and A (6 ft)) = 6.6 ft
Calculation Example 2
Permissable gross weight of machine = 23,000 lbs

(Therefore the minimum distance from the pit a = 3.3 feet)
Type of ground = compact, solid; depth of pit = 2 feet
(Therefore the additional safety clearance from the pit A = 1 x 2 ft = 2 ft)
Required distance from pit (i.e., greater of a (3.3 ft) and A (2 ft)) = 3.3 ft
A820062_05_0208D
511
Operation
3. Ensure that there is clearance to extend the outrigger legs. The

outrigger legs must be fully swung out or extended. As shown
below, the outriggers danger zone is the zone in which the
outriggers are swung out or extended:
12100801
The Outrigger Legs Must Always Be Fully Swung Out and Extended
The Outriggers Danger Zone
Danger of crushing
Since there is a danger of crushing in the swing--out and extension zone
for the outriggers, you should secure this area and keep it under
constant observation. You must halt work immediately and press the
EMERGENCY SHUT--DOWN button if anyone enters this danger zone.
512
A820062_05_0208D
Operation
4. As shown in the diagram below, ensure that there are no voids or

other ground irregularities under the outrigger feet:
22102802
No Voids or Other Ground Irregularities Under The Outrigger Feet
Caution
Do not bridge voids or other ground irregularities with support blocks
or timber blocks, since these blocks may break if a point load is applied
to them. If these blocks break, the machine will not have the necessary
stability and may tip over.
5. As shown in the diagram below, ensure that the outrigger feet are
set up on level supporting ground:
22102803
Outrigger Feet Should Only Be Set Up on On Level Supporting Ground
A820062_05_0208D
513
Operation
6. Verify that the machine is supported in accordance with the corner

bearing loads and the loadbearing capacity of the supporting ground
(permissible ground pressure), by performing the following steps:
A. Ask site management for the maximum permissible ground
pressure (i.e., loadbearing capacity of the supporting ground).
B. Determine whether the outrigger support area is adequate by
calculating the maximum possible ground pressure that each
outrigger leg can exert using the following equation:
Max possible ground pressure =

Max.
Machine corner bearing load

Support area
Corner Bearing Load
lbs
kN
t
The Corner Bearing Load is Stated on Each Outrigger Leg
Note
The support area is adequate if the maximum possible ground pressure
is less than the maximum permissible ground pressure.
C. If the maximum possible ground pressure is greater than the
maximum permissible ground pressure, then it is necessary to
increase the support area under the outrigger feet with
Putzmeister support blocks or timber blocks (refer to timber
block length table on page 5-16).
514
A820062_05_0208D
Operation
Support Block
12100501
Putzmeister support blocks are made of multi--ply glued timber. The support
blocks are 23.6 in x 23.6 in (60 cm x 60 cm) in size.
Danger
Always use 4 timber blocks with a cross--section of 6 in x 6 in.
(15 cm x 15 cm) each and of the length shown in the table on the next
page.. Place the 4 timber blocks together beneath the support block as
shown. The support block and the timber blocks must always be free
from grease, oil, ice, etc., as otherwise the support leg could slip off.
12100502
A820062_05_0208D
515
Operation
Length of the Timber

Blocks Required
Corner bearing load in kN
(see support leg)
50
75
The table below shows the minimum length of the timber blocks
required.
100
125
150
175
200
225
250
275
300
325
350
375
400
Metric Tons
5.0
7.5
10.0 12.5 15.0 17.5 20.0 22.5 25.0 27.5 30.0 32.5 35.0 37.5 40.0
(1000Kg=2205Lbs)
11,250 16.875 22,500 28,125 33,750 39,375 45,000 50,625 56,250 61,875 67,500 73,125 78,750 84,375 90,000
Pounds
Permissible ground
pressure
kN/m2
15 cm x 15 cm (6 in x 6 in) timber block lengths in cm (in)
(Lb/in2)
Undisturbed soil
100
(14.5)
Asphalt
200
(min. 20 cm thick)
(29)
Hardcore
250
(compacted)
(36.3)
Clay, coarse clay
300
(firm)
(43.5)
Mixed stone
350
(firm)
(50.8)
Layered gravel
400
(firm)
(58)
500
(72.5)
750
(109)
Rock
1000
(fractured, weathered) (145)
84
(33)
125
(50)
167
(66)
84
(33)
209
(83)
105
(42)
84
(33)
Use Putzmeister
support blocks
23.6in x 23.6in
(60cm x 60cm)
without additional
timber blocks
250
(99)
125
(50)
100
(40)
84
(33)
146
(58)
117
(46)
98
(39)
84
(33)
167
(66)
134
(53)
112
(44)
96
(38)
84
(33)
Supporting ground is not

suitable for outriggers
150
(60)
125
(50)
108
(43)
94
(37)
75
(30)
167
(66)
139
(55)
119
(47)
105
(42)
84
(33)
153
(61)
131
(52)
115
(46)
92
(37)
167
(66)
143
(57)
125
(50)
100
(40)
155
(61)
136
(54)
109
(43)
73
(29)
167
(66)
146
(58)
117
(46)
78
(31)
157
(62)
125
(50)
84
(33)
167
(66)
134
(53)
89
(35)
Note
You should use the next higher value if the corner bearing load is not
exactly the same as the value specified in the table (e.g. actual corner
bearing load of the machine = 180 kN; you must take the timber block
length from the 200 kN column from the table).
516
A820062_05_0208D
Operation
Example 1

(see support leg)
50
75
100
125
150
175
200
Metric Tons
5.0
7.5
10.0 12.5 15.0 17.5 20.0
(1000Kg=2205Lbs)
11,250 16.875 22,500 28,125 33,750 39,375 45,000
Pounds
Permissible ground
pressure
kN/m2 15 cm x 15 cm (6 in x 6 in) timber block lengths in
cm (in)
(Lb/in2)
Undisturbed soil
100
(14.5)
Asphalt
200
(min. 20 cm thick)
(29)
Hardcore
250
(compacted)
(36.3)
Clay, coarse clay
300
(firm)
(43.5)
Mixed stone
350
(firm)
(50.8)
Layered gravel
400
(firm)
(58)
500
(72.5)
84
(33)
125
(50)
167
(66)
84
(33)
Use Putzmeister
support blocks
23.6in x 23.6in
((60cm x 60cm))
without additional
timber blocks
209
(83)
105
(42)
84
(33)
250
(99)
125
(50)
100
(40)
84
(33)
146
(58)
117
(46)
98
(39)
84
(33)
167
(66)
134
(53)
112
(44)
96
(38)
84
(33)
Soil type: firmly layered gravel

Permissible ground pressure
400 kN/m 2
150 kN (15 metric tons or 33,750 lbs)
Timber block length
not required
In this example it is sufficient to place Putzmeister 60 cm x 60 cm

(23.6 in x 23.6 in) support blocks beneath the support feet.
A820062_05_0208D
517
Operation
Example 2

(see support leg)
50
75
100
125
150
175
200
Metric Tons
5.0
7.5
10.0 12.5 15.0 17.5 20.0
(1000Kg=2205Lbs)
11,250 16.875 22,500 28,125 33,750 39,375 45,000
Pounds
Permissible ground
pressure
kN/m2 15 cm x 15 cm (6 in x 6 in) timber block lengths in
cm (in)
(Lb/in2)
Undisturbed soil
100
(14.5)
Asphalt
200
(min. 20 cm thick)
(29)
Hardcore
250
(compacted)
(36.3)
Clay, coarse clay
300
(firm)
(43.5)
Mixed stone
350
(firm)
(50.8)
Layered gravel
400
(firm)
(58)
500
(72.5)
84
(33)
125
(50)
167
(66)
84
(33)
209
(83)
105
(42)
84
(33)
250
(99)
125
(50)
100
(40)
84
(33)
Use Putzmeister
support blocks
23.6in x 23.6in
((60cm x 60cm))
without additional
timber blocks
146
(58)
117
(46)
98
(39)
84
(33)
167
(66)
134
(53)
112
(44)
96
(38)
84
(33)
Soil type: compacted hardcore

Permissible ground pressure
250 kN/m 2
150 kN (15 metric tons or 33,750 lbs)
Timber block length
at least 100 cm (40 inches)
In this example you must place 4 timber blocks with a cross--section of

15 cm x 15 cm (6 in x 6 in) and a length of at least 100 cm (40 in) beneath
the support feet in addition to the Putzmeister 60 cm x 60 cm (23.6 in x
23.6 in) support blocks.
7. Check the clearance for extending the placing boom.

8. Ensure that the setup site is adequately ventilated. Exhaust gases
can be fatal.
Danger of poisoning
Vehicle exhaust gases contain constituents which can be lethal or carcinogenic. Set the machine up at an adequately ventilated site or vent
the exhaust gases away from where you are working.
518
A820062_05_0208D
Operation
9. With truck engine running, transmission in neutral, and parking

brake on, engage concrete pump power take-off (PTO), by
performing the following steps:
Note
If your truck engine is equipped with electronic diesel control (EDC)
you must apply the parking brake before you switch on the power take-off. Otherwise you will not be able to increase engine speed during
pumping operations. This is also the case if you release the parking
brake and apply it again while the power take--off is switched on.
Caution
The following points must be complied with to prevent damage when
using power take-off gearboxes:
The transmission must be in neutral when the power take-off
gearbox is switched on or off.
If the engine was shut down during pumping operations and your
truck has a manual transmission, you must depress the clutch before
starting it up again.
A. Position concrete pump PTO switch (located on right side of
drivers seat) to PUMP position (PTO engaged).
B. Verify that green PUMP light illuminates.
C. If your vehicle has a manual transmission, perform these steps:
Push in clutch pedal (clutch disengaged).
Place truck transmission in proper pumping gear.
Let clutch pedal out (clutch engaged).
D. If your vehicle has an automatic transmission, shift selector
from N (Neutral) to D (Drive). The display indicates 4
signifying that truck transmission is in 4th gear lock-up (i.e.,
the truck transmission will remain in 4th gear). If engine is
switched off or transmission shifted to Neutral, repeat Step 9 to
reset interlocks for 4th gear lock-up PTO operation.
Note
The truck engine will automatically throttle up approximately 200 RPM
when the PTOs are engaged and the E--stops are cleared.
A820062_05_0208D
519
Operation
5.3.3
Remote Control
Setup
Depending on your machines equipment, you are able to operate it

-- using radio remote control,
-- using cable remote control, or
-- directly from the machine in emergency operation.
Danger
Before starting to use the remote control, press the EMERGENCY
SHUT--DOWN button on the remote control and shift all control and
monitoring devices on the remote control to the 0 position. The
boom or the pump can otherwise execute unintended movements as
soon as the remote control is switched on.
Caution
Carry the remote control in such a way that no control elements can be
actuated unintentionally. Do not damage the remote control cable. Incorrect functions may otherwise occur.
Never put the remote control down when the machine is in ready mode.
If this cannot be avoided in exceptional circumstances, press the
EMERGENCY SHUT--DOWN button in, disconnect the remote control
and lock the remote control unit away in the drivers cab.
10. If using a cable remote control system, perform the following steps:
Note
You can only execute boom movements in black and white with the
cable remote control (i.e., the boom always moves at its maximum
speed, no matter how much you move the boom control lever).
Danger
Black/white control can lead to jerky movements and significant
swaying of the boom, which represents a high risk of an accident to the
operator guiding the hose. Flip the toggle switch boom speed to the
snail symbol and the rotary controller to 0 before beginning to use
the cable remote control. This ensures that the first boom movements
after the remote control is switched on will be executed slowly and you
will be able to get used to them.
520
A820062_05_0208D
Operation
A. Verify that remote cable is connected between the electric

control box and cable remote control box.
Note
On some control cabinets, the socket into which the cable remote
control is plugged is located on the control cabinet casing. On some
control cabinets the socket is fixed to the truck superstructure and
connected to the control cabinet by a cable.
10504600
Connecting the Cable Remote Control
B. Verify that Local-Remote switch on electric control box is in

Remote position.
C. At cable remote control, perform the following steps:
Verify that all function switches are off.
Twist emergency stop (E-stop) button to allow it to pop out.
D. Ensure electric control box and other E-stops are released.
Note
The horn/outrigger/reset switch is used to clear the E-stop mode.
Clear the E-stop mode by pushing the horn switch up once. The first
press clears the E-stop. The second and subsequent presses blow the
horn. If the horn will not blow, recheck cable connections, E-stop
buttons, and power supplied to the electric control box.
A820062_05_0208D
521
Operation
11. If using a proportional radio remote control system, perform the

following steps:
Note
Proportional control means:
The boom moves slowly on a small movement of the boom control
lever.
The boom moves at its maximum speed on a large movement of the
boom control lever.
A. Verify that radio receiver is connected to electric control box.
B. Verify that Local-Remote switch on electric control box is in
Remote position.
C. Ensure transmitter has charged battery inserted.
D. Release E-stop button, by twisting button to allow it to pop out.
E. Verify that all functions switches are off.
F. Turn transmitter power switch on.
G. Ensure electric control box and other E-stops are released.
Note
The horn/outrigger/reset switch is used to clear the E-stop mode.
Clear the E-stop mode by pushing the horn switch up once. The first
press clears the E-stop. The second and subsequent presses blow the
horn. If the horn will not blow, recheck cable connections, E-stop
buttons, and power supplied to the electric control box.
522
A820062_05_0208D
Operation
5.3.4
Outriggers Setup
12. On cable or radio remote control, place horn/outrigger/reset switch
in outrigger position.
Danger
You must have read the safety regulations and have completed the
operations for setting up the machine before you begin setting out the
machine outriggers. The machine outriggers may only be used under the
following conditions:
the pump drive engine is running;
the power take--off is engaged (i.e., the machine is set to pumping
operations);
the Outrigger function has been selected at the remote control or
on the control block.
It is absolutely forbidden to move the outriggers manually (mechanically).
12101600
Do not move the hydraulic support legs manually
A820062_05_0208D
523
Operation
13. As shown in the diagram below, unlock the outrigger legs by

A. Pull out the spring pin (1).
B. Pull the lever on the snaplock upwards (2).
2
12100101
Outrigger snaplock -- You must unlock the outrigger legs before you are able to
extend them or swing them out.
Note
Extendable support legs are automatically locked by the snaplock once
the support leg is fully extended.
Once the legs are locked, replace the spring pin. The snaplock cannot
now be opened unintentionally and the support leg remains locked in
the end position.
The snaplock has no function once swing--out support legs have been
swung out. Do not replace the spring pin; in this way the supports will
be locked automatically when they are swung back.
Before driving off, make sure that all the snaplocks are secured by a
spring pin.
Danger
Do not attempt to reposition any outrigger unless placing boom is in
stowed position. The placing boom will not operate when the
outriggers are activated.
524
A820062_05_0208D
Operation
14. Use the left outrigger controls to lower the left rear and left front
outriggers as follows:
A. Extend the left rear outrigger.
B. Lower the left rear outrigger.
C. Extend the left front outrigger.
D. Lower the left front outrigger.
Caution
Only execute one outrigger at a time. Observe leveling bubble and
ensure that truck remains level as each outrigger is positioned.
Stability is jeopardized at a deviation from horizontal of 3_ or more.
5d
3d
1
32100101
Leveling bubble
1
Permissible range of tilt
15. Repeat Step 14 for the right outriggers.

Note
Extend the outriggers one after the other until the truck lifts about 5 cm
(2 inches) from the ground. The rear wheels may be in light contact
with the ground in order to achieve steady pumping.
A820062_05_0208D
525
Operation
Danger
All four outriggers must be completely swung out and extended to
stabilize the truck-mounted concrete pump placing boom through
swing, unfolding, extending, and elevate functions. Wrong positioning
or partial opening of outriggers can cause machine instability and risk
of overturning.
Danger
Uncontrolled movements of the outrigger legs increase the risk of an
accident. They are possible if:
the hydraulic system has not been carefully bled;
pipes or threaded unions are leaking;
there is too little hydraulic fluid in the reservoir;
the switch is defective or dirty.
In this case, the support legs may move as soon as the preselect switch
is actuated. Halt work immediately. You can continue working only
after the causes have been remedied and perfect functioning of the
machine is ensured.
Note
Before closing the outriggers, ensure that the boom is correctly closed
and resting on the support in its housing. To close the outriggers,
follow inversely the instructions for opening. When closing the
stabilizers, move to a safe position so as not to be hit by the outriggers.
16. After outriggers are positioned, on the radio or cable remote
control, return the horn/outrigger/reset switch to its center (off)
position to activate the boom controls.
526
A820062_05_0208D
Operation
5.4
Boom Movements
Before you extend the placing boom you must read the safety
regulations and complete the operations to set up the machine.
You may only extend the placing boom once you have set the machine up
properly. Comply with the safety regulations of the country in which you
are using the machine in every case.
Prohibited Activities
Prohibited Activities
Danger
Avoid the following actions. They overload the placing boom and will
lead to damage and jeopardize persons:
lifting and transporting loads;
allowing the placing boom to strike an obstacle;
pushing with the placing boom, in order to move an obstacle out of
the way, for instance;
tearing away a trapped end hose by force.
Overlapping Working
Ranges
Caution
Take note of the working ranges of other machinery that is working
near you (e.g., cranes, other concrete placing booms, etc.)
A820062_05_0208D
527
Operation
5.4.1
Restrictions on Use
Bad Weather and
Storms
Extreme weather conditions, such as gales, storms or low temperatures

restrict the use of the boom, or can even make its use impossible.
Shift the placing boom to the transport position in the event of storms
or bad weather.
-- Placing booms with a vertical reach of 42 m or more (M 42 and
larger) may not be operated in winds of force 7 or greater (wind
speed 31.1 miles/hr (50 km/hr) and higher).
-- Placing booms with a vertical reach less than 42 m (< M 42) may
not be operated in winds of wind force 8 or more (wind speed
38.5 miles/hr (62 km/hr) and greater).
Higher wind speeds jeopardize stability and the safety of structural
elements. There is a risk of lightning strike in the event of storms.
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 force 7 and greater, green leaves break from trees and
there is a perceptible hindrance to walking in the open.
In winds of force 8 and greater, small branches break from trees and
walking outside is made significantly more difficult.
Cold Weather
528
The boom may not be used in temperatures below minus 15 _C (+5 F).
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 realistic
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. During cold weather, if hydraulic fluid is not at
normal operating temperature, then boom operation may be sluggish.
A820062_05_0208D
Operation
5.4.2
Danger Zone
22000500
The danger zone when working with the boom is the zone over which the boom
is slewed.
Danger
There is a risk of injury from parts of the delivery line falling beneath
the slewing circle of the placing boom. There is a risk of injury from
falling concrete beneath the end hose.
You should therefore secure the danger zone. Keep the danger zone
under constant observation.
You must halt work immediately and press the EMERGENCY
SHUT--DOWN button if anyone enters the danger zone.
A820062_05_0208D
529
Operation
5.4.3
High- Voltage Lines
22000400
Caution in the Vicinity of High--Voltage Lines
Danger
A spark can jump across from high--voltage lines even if you just
approach them and this will energize the machine and the surrounding
area. YOU MUST THEREFORE MAINTAIN AT LEAST 17 FEET
FROM ANY HIGH-VOLTAGE LINES.
530
A820062_05_0208D
Operation
5.4.4
Signal of Boom
Movements
Sound the Horn First, Then Move
Note
Move the placing boom with cautious operation of the controls.
Maintain visual contact with the site of concrete placement.
Warn by sounding the horn before you move the boom.
5.4.5
Temperature-Related
Cylinder Movements
The hydraulic fluid heats up to an average temperature of 140-- 158F

(60-- 70 C) during operation because of the friction in the lines.
When the hydraulic fluid cools, its volume reduces as cold hydraulic
fluid has a smaller volume than does hot hydraulic fluid. This causes
the cylinders on the boom, swing--out legs and outriggers to retract a
little, which causes the boom to move and the outrigger feet to sink.
Caution
The boom can move during lengthy pauses in work due to cooling of
the hydraulic fluid. For this reason you should never leave the boom in
the extended position during breaks in working.
In addition, you must keep the outriggers under constant observation
while the machine is in operation. You may have to readjust the swing-out cylinders and outrigger cylinders.
The extent to which the boom and the truck move depends on the
extent to which the various boom and outrigger cylinders have been
extended and the magnitude of the temperature difference in the
hydraulic fluid.
A820062_05_0208D
531
Operation
5.4.6
Uncontrolled Boom
Movements
The following defects may be the cause of uncontrolled boom

movements:
-- Malfunctions in the remote control circuit
-- Malfunctions on the boom control block
-- Lines, threaded unions or boom cylinders leaking
-- Defective mono-isolator on the boom cylinder
-- Hydraulic system not carefully bled
-- Insufficient hydraulic fluid in the reservoir
-- Cooling of the hydraulic fluid
In this case, the boom may move as soon as the remote control is
switched on. Halt work immediately. You can continue working only
after the causes have been remedied and perfect functioning of the
machine is ensured.
Note
Whatever the reason for the uncontrolled movements of the boom, you
must halt the work on site and have the cause of the breakdown
determined and rectified by qualified personnel.
Danger
In no event should you first press the EMERGENCY SHUT--DOWN
button if the boom starts uncontrolled movements. Should you do this
you will have no ability to counteract the movement.
Countermeasures
You must proceed as follows if the boom starts uncontrolled

movement:
1. Counter the uncontrolled movement immediately and attempt to
steer the boom out of the danger zone and bring it to rest under
control.
2. If the uncontrolled boom movement continues, despite
countermeasures, press the EMERGENCY SHUT--DOWN button.
Note
Repeated practice is required to ensure that it will be possible to implement the measures described above in an emergency.
532
A820062_05_0208D
Operation
5.5
Hand Signals for

Boom and Pumping
Operations
A820062_05_0208D
Pump operators and persons guiding them must agree on unambiguous

hand signals before commencing work. Suggestions for the most
important hand signals are made in this section. They are based on
ACPA Safety Manual Hand Signals. The direction of movement is
specified from the machine operators direction of view.
533
Operation
5.6
Extending the 36Z

4- Section Boom
Proceed in the sequence specified to extend the 36Z 4-section boom.

The boom must be folded in the reverse sequence.
Note
You must unfold the arm assembly to the side of the truck to be able to
achieve the lowest possible unfolding height of 28.5 ft (8.7 meters).
Caution
The hydraulic fluid is warm when you fold the arm assembly. It then
cools and the pressure in the cylinder drops. If you then raise arm 1,
the remaining arms become depressurized and may fall down. You must
therefore draw the arm assembly together briefly before raising arm 1.
Always observe the specified sequence for folding and unfolding the
boom. Failure to comply with the sequence may allow the crank lever
in the C hinge to compress the delivery line, adjacent hydraulic
cylinders, or other components.
Danger
Arms 3 and 4 must not be moved behind the C hinge when unfolded or
partially unfolded during the entire boom operation. In this arm
position, the rod side C cylinder hydraulic pressure is so high that the
pressure limiting valve responds and the boom will gradually slump.
There is also a risk of uncontrolled boom movements.
534
A820062_05_0208D
Operation
1. As shown below, draw the arm assembly together by: (1) dropping
arm 2 and 4 briefly, and (2) raising arm 3 briefly.
Drawing the Arm Assembly Together
2. As shown below, raise arm 1 approximately 45.
45
A820062_05_0208D
535
Operation
3. As shown below, slew the placing boom approximately 180.
180
Caution
Take care when unfolding arm 2 that you do not damage the drivers
cab or other elements. It may be necessary to raise arm 1 higher.
4. As shown below, raise arm 2 until it is almost vertical.
536
A820062_05_0208D
Operation
Caution
Before you unfold arm 3, you must open arm 4 by approximately 15_,
so that the boom tip is approximately 3.28 ft (1 meter) away from the
C hinge (hinge between arm 2 and arm 3). The crank lever on the C
hinge will be forced against the bend at the boom tip if you do not
follow this instruction.
5. As shown below, open arm 4 approximately 15_.
15
6. As shown below, unfold arm 3 approximately 45.
45
A820062_05_0208D
537
Operation
7. As shown below, unfold arm 4 enough to allow you to unlock the

end hose.
8. As shown below, unlock the end hose by pulling the two locking
levers downwards.
538
A820062_05_0208D
Operation
5.6.1
Impermissible
Working Range
A820062_05_0208D12
Impermissible Working Range

1
Range in which work with the end hose is not permitted
Caution
The end hose may not be shifted behind the vertical.
A820062_05_0208D
539
Operation
5.7
Pumping Operations
You must carry out the following operations before you start to pump:
-- Set the machine up for work properly (see Starting Up section).
-- Set the machine supports out properly (see Supporting the
Machine section).
-- Carry out all necessary function checks (see Function Checks
section).
-- Extend the boom to the desired working position (see Extending the
Placing Boom section).
5.7.1
Hazards
Dangers to the life and limb of site personnel can arise at many points
during pumping operations. You can minimize these dangers by
observing the following notes.
End Hose Striking Out
2
1
2
12500500
Maximum end hose length 13.1 ft (4 m)

Danger zone = 2 end hose length = 26.2 ft (8 m)
Danger
There is a risk of injury in the area around the end hose if the end hose
swings out violently when starting to pump, after a blockage has been
freed, or during washing out. This zone is twice the end hose length in
diameter.
The end hose must be allowed to hang freely.
Ensure that nobody is standing in the danger zone. Keep the danger
zone under constant observation.
You must halt work immediately and press the EMERGENCY
SHUT--DOWN button if anyone enters the danger zone.
540
A820062_05_0208D
Operation
Incorrect Use of
the End Hose
12501901
Danger
Never bend the end hose over. Never attempt to straighten a bent end
hose by increasing the pressure. The end hose must not be inserted in
the concrete. Extension of the placing boom and end hose beyond the
length specified on the boom rating plate is forbidden. The end hose
must be secured against falling.
Sucking in Air
10800114
Agitator Hopper
Escaping Compressed Air
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.
A820062_05_0208D
541
Operation
5.7.2
Notes on Correct
Pumping
To supplement the notes given here, you will find comprehensive

information on the following subjects in our Concrete technology
pamphlet (BP 2158):
-- Concrete components
-- Properties of freshly--mixed concrete
-- Properties and conditions of freshly--mixed concrete when pumping
-- Guide to avoid faults
-- Specifications and regulations of the Technical Regulations
You may request this pamphlet from Putzmeisters After Sales
department should you not already have a copy.
Bouncing Boom
Note
If the boom bounces very heavily in pumping operations, check the
support and correct it as required. Calm pumping is achieved if the
rear wheels are in light contact with the ground. Do this by retracting
the rear support feet until the rear wheels are in ground contact and
then retract the support feet about another .4 inches (1 cm).
If the support is correct, reduce the pump speed or change the boom
position.
The boom can also bounce if air is taken in and compressed in the
delivery line. You should therefore always make sure that the agitator
hopper is always filled with concrete to the mixer shaft and that no air
is sucked in.
Favorable Boom
Position
32202300
Last Arm in a Horizontal Position
542
A820062_05_0208D
Operation
Note
A horizontal position of the last arm is favorable for pumping.
If the last arm is lower than the horizontal, the concrete in this part of
the delivery line will flow more quickly as a result of its self--weight.
The flow velocity is lower if the arm position is horizontal, and thus the
wear on the delivery pipes and the end hose is less.
When the pump is stopped, only the content of the end hose flows out if
the arm position is horizontal; the content of the delivery line can flow
out if the arm position is below the horizontal.
The strokes of the pump cause forces to act along the delivery line and
thus along the boom. If the last arm is vertical, the forces also act
vertically on the boom end and move the boom up and down. If the arm
position is horizontal, the boom is moved forwards and backwards,
which causes a light rocking motion.
Damping Valve
As shown in the diagram below, the damping valve is used to control

the switching speed of the transfer tube.
20203903
Hare: Damping Valve Switch Position Open

Snail: Damping Valve Switch Position Closed
Note
You must close the damping valve when you are pumping soft
consistence concrete (snail symbol) as otherwise the transfer tube
switches over too harshly.
You must open the damping valve (hare symbol) when you are pumping
stiff consistence concrete as the concrete has a damping effect.
A820062_05_0208D
543
Operation
5.7.3
Starting Pumping
The process from the start of concrete pumping to the time at which a
continuously flowing concrete stream exits from the end hose is known
as starting to pump. The entire delivery line must be wetted at the start
of pumping operations by performing the following steps:
Starting Pumping with Thin Concrete
1. Insert two sponge balls into the delivery line through the wash--out
port.
2. Pour approximately 0.65 yd3 (0.5 m3) thin concrete into the hopper.
3. Switch the agitator on.
4. Slowly pump the concrete into the delivery line. The process of
starting to pump with thin concrete is completed when the two
sponge balls and a solid concrete stream exit from the end hose.
Note
You must begin pumping with a priming agent if the delivery lines are
new, or if the delivery line has not been used for a long time. This
priming agent could be either a cement-water mixture (grout) or a
specially designed agent such as the Putz Pack Primer.
5.7.4
Pumping
Commence pumping concrete by performing the following steps:

1. Mix the concrete vigorously in the truck mixer at maximum speed.
Ensure that the concrete mix is uniformly prepared. Correct mixing
of the concrete influences pumping performance.
2. Add concrete additives (deflocculants, set retarding admixtures) and
mix for at least a further four minutes.
3. Pour the concrete from the truck mixer, silo, etc. into the agitator
hopper.
4. Switch the agitator on.
5. Begin delivery.
544
A820062_05_0208D
Operation
Note
Start with a low output and increase this continuously after several
cubic yards (meters).
Breaks in Pumping
You should avoid breaks in pumping as far as possible, as the concrete

in the delivery line can start to set, or can become segregated due to 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 high slump
(i.e., concrete that has a tendency to separate the grout from the
aggregate) as the vibrations can segregate the concrete; When you
restart pumping, you must leave the pump switched to reverse
pumping until the transfer tube switches 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.
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.
The boom can sink during lengthy breaks in pumping as a result of the
hydraulic fluid cooling. For this reason you must never leave the boom
unattended in the extended position during breaks.
A820062_05_0208D
545
Operation
5.7.5
Possible Faults
Faults may occur even if you have observed all the notes on correct
pumping. This section lists the faults occurring most frequently, and
indicates how to rectify them.
Blockages
1
3
11000601
1
2
3
Wedged aggregate
Cement paste
Boundary layer
The following faults can lead to blockages:

-- delivery line insufficiently wetted;
-- transfer tube leaking;
-- lines leaking;
-- concrete leavings in the transfer tube and delivery pipes;
-- unfavorable 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.
546
A820062_05_0208D
Operation
Overheating
Continuous operation under high loading can lead to overheating of the

hydraulic fluid. All pumps have a thermo--electrical cut--out. The pump
is automatically shut down if the fluid heats up to over 90 _C. Proceed
as follows to prevent this:
1. Check that the hydraulic fluid radiator is operating correctly. If not,
you can switch it on using the toggle switch on the control cabinet.
2. Reduce the output.
3. As shown in the diagram below, fill the water box with fresh water
as soon as the fluid temperature rises above 80_C.
Cooling -- Water box is shown with grate removed for illustration purposes only.
Grate should not be removed unless a qualified mechanic is performing an
approved maintenance procedure.
4. Change the water continuously if the temperature continues to rise.

5. Look for the cause of fluid overheating and rectify it.
6. As shown in the diagram below, if you absolutely must supply
additional cooling, direct the water jet onto the drive cylinders and
the piston rods of the drive cylinders.
Additional Cooling
Caution
Never spray water on the hydraulic fluid reservoir because damage
may be caused to the hydraulic pump. Also never use sea water or
water containing salt for cooling because this will destroy the chrome
layer on the delivery piston rods and delivery cylinders.
A820062_05_0208D
547
Operation
Restarting After
Overheating
If the pump was switched off because of overheating, restart the pump
by performing the following steps:
1. Switch the pump off.
2. Never switch the engine off, as the hydraulic fluid radiator must
remain in operation.
3. Refresh the water in the water box.
4. Wait until the hydraulic fluid has cooled if you are not able to find
the fault immediately.
5. Once the red indicator lamp has extinguished, switch the pump back
on and continue pumping slowly at reduced output.
6. Determine the cause of the fluid overheating once pumping
operations have been completed and rectify the fault.
548
A820062_05_0208D
Operation
5.7.6
Special Cases
On some construction sites, it may be the case that the net reach of the
boom is not adequate. You then have the option of connecting a
continuation delivery line to the boom tip or, if your machine is
equipped with a lateral outlet, connecting a delivery line there.
Continuation
Delivery Line
Connect Continuation Delivery Line
Caution
No forces must be transferred from the fixed delivery line to the boom
or vice versa.
The stationary delivery line may not place additional loading on the
boom. This will jeopardize the stability of the machine.
The delivery hose should not be bent or stretched. Blockages can occur
if it is bent. If it is stretched out, forces may be transmitted which can
lead to damage to the structure, delivery hose or boom.
The boom can sink during pumping operations and place the delivery
hose under tension as a consequence of cooling of the hydraulic fluid
in the boom cylinders. This can cause forces to be transferred or the
delivery hose to tear. You should therefore keep the delivery hose under
constant observation.
1. Extend the boom to bring the last arm approximately 4.9--6.6 ft
(1.5--2 m) from the stationary delivery line.
2. Dismantle the end hose.
3. Mount a 9.8 ft (3 m) long delivery hose in place of the end hose.
4. Connect the delivery hose and the fixed delivery line using a SKH
attachment coupling. Use an A seal as the seal.
5. Fasten the SKH attachment coupling securely to the structure.
A820062_05_0208D
549
Operation
5.8
Cleaning
5.8.1
Preparations for
Cleaning
Prior to cleaning the concrete pump, perform the following steps:

Note
Concrete leavings that are deposited inside the delivery line or transfer
tube can cause damage and will reduce the cross-section as they
accumulate. A clean delivery line and transfer tube is therefore
indispensable if you wish to be able to start pumping without problems
on the next job. When cleaning, adhere to the following instructions:
Concrete leavings deposited around the wear ring can impair its
function. For this reason, thorough flushing of the wear ring is
required at the end of a job, unless the next pumping job follows
within 30 minutes.
Only use cold water at a maximum water pressure of 5 bar (73.5 psi)
for cleaning all painted surfaces in the first four weeks of using the
machine. Do not use any aggressive cleaning agents. The paint is
not fully cured until after this period and you will then be able to use
steam jet equipment or other devices.
Never use sea water or other water containing salt for cleaning
purposes. You must rinse off any sea water that gets on the machine.
Lock the remote control units away in the drivers cab during
cleaning operations. The remote control units do not have a
watertight casing. Execute the machine functions required during
cleaning operations from the control cabinet.
Danger
Leave the hopper grate closed during all cleaning operations, since
you could be trapped by the agitator.
10800500
Do not reach into the hopper.
550
A820062_05_0208D
Operation
1. Find an appropriate use for the leavings to help in environmental

protection.
The leavings should be used on the construction site. The leavings
should be used as building rubble or be recycled if this is not possible:
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 concrete
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
reinforcing steel into a hook and insert it in the concrete. Once the
concrete has cured, you can transport the lump of concrete away
using a site crane.
2. Ensure that you have a sufficient numbers of sponge balls and other
cleaning accessories to clean the machine properly.
1
3
Sponge Balls and Other Accessories

1
2
3
4
A820062_05_0208D
Sponge pig
Sponge cube
Sponge ball
Wash-out pig
551
Operation
3. As shown in the diagram below, 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 simultaneously seals off the delivery line.
2
3
4
31201501
Catch Basket
1
2
3
4
Coupling
Catch basket (closed pipe section)
Spring pin (on both sides)
Catch bracket
Danger
Remember that:
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.
A catch basket on the end of the delivery line is an absolute
requirement 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.
There is an increased risk of accident when cleaning with
compressed air. The cleaning operation must only be carried out by
a subject expert or under his supervision. Putzmeister accepts no
liability for damage caused by incorrect implementation of
compressed air cleaning. All persons participating in the cleaning
operation must be instructed in the safety regulations.
552
A820062_05_0208D
Operation
4. As shown in the diagram below, use the wash-out adaptor when the
machine is cleaned using water under pressure or compressed air.
Wash-Out Adapter
1
2
3
4
A820062_05_0208D
Connection for water or compressed air

Isolating valve for connection
Pressure dump bend
Pressure dump cock
553
Operation
5. If you wish to use cement bags for high pressure water cleaning,
perform the following steps:
A. As shown in the diagram below, roll up 1 -- 2 empty cement
bags together.
B. Immerse the rolled--up cement bags in water for about
5 minutes before starting the cleaning operation.
Rolled--up Cement Bags
Note
Cement bags soaked in water and rolled up have proved useful when
cleaning the delivery line using water under pressure. The cement bags
prevent the washing water penetrating the concrete, flushing the
concrete out and causing blockages.
Note
You may also prepare a short pipe section containing the cement bags
and a wash--out sponge before you start the cleaning operation.
554
A820062_05_0208D
Operation
6. Prior to cleaning the wear ring and seal ring on the transfer tube, the
water hose must be marked to ensure that the hose does not get cut
by the switching transfer tube during cleaning. Mark the water hose
by performing these steps (refer to diagram below):
A. 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.
B. Mark the measured length on the hose with adhesive tape, or
similar.
Note
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.
Danger
The machine must be switched off and the hydraulic system, including
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.
Marking the Water Hose

1
A820062_05_0208D
Adhesive tape marking
555
Operation
5.8.2
Delivery Line
Cleaning Methods
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 available.
On the next page, you will find a summary of delivery line cleaning
methods. The symbols used in the summary are explained below:
Explanation of Symbols
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 placement. 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 placement to the hopper.
The delivery line has been disconnected from the
concrete pump. The leavings are forced forwards from
the start of the delivery line to the site of concrete placement using an external force (compressed air or water
under pressure). Cleaning is from the start of the delivery line to the site of concrete placement.
The delivery line has been disconnected from the
concrete pump. The leavings are forced backwards from
the 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
556
A820062_05_0208D
Operation
Summary of Delivery Line Cleaning Methods

Leavings
from
to
Delivery line
Boom
om deli
livery lline
Truck--m
Tr
mount
nted con
oncretee pump
mp
Method of
cleaning
no onwards delivery line connected to the
boom tip
with onwards
delivery line
connected to the
boom tip
Compressed air
Water under pressure
only with
special
equipment
Suction cleaning
Compressed air
only with
special
equipment
Suction cleaning
Compressed air
Lateral outlet

Suction cleaning
S
Station
nary delivery
de ry linee
Compressed air
Riser
only with
special
equipment
Suction cleaning
Compressed air
Downpipe
only with
special
equipment
Suction cleaning
A820062_05_0208D
557
Operation
5.8.3
Delivery Line Suction

Cleaning
To clean the delivery line using the suction cleaning method, perform
the following steps:
Note
Suction cleaning is the simplest and least hazardous method of
cleaning the delivery line.
1. 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.
2. As shown in the diagram below, insert a water--soaked wash--out
sponge (cube) into the end hose outlet:
Inserting a Water-Soaked Wash-Out Sponge
3. As shown in the diagram below, shift the placing boom into a

uniformly rising position. This makes it easier to pump the
concrete back as the concrete flows back under its own weight.
Shifting the Placing Boom into a Uniformly Rising Position
558
A820062_05_0208D
Operation
4. Switch the pump to reverse pumping and then turn the pump on.
This will cause the concrete and wash-out sponge to be pumped
back through the delivery line.
5. As shown in the diagram below, tap on the delivery line with a
piece of hardwood (hammer handle) just ahead of the cleaning eye
during the washing out process.
Note
Tapping produces deep dull noises when 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.
20006203
Checking for the Wash-Out Sponge by Tapping on the Delivery Line with Hammer
Handle
6. Switch the pump off as soon as the wash-out sponge has passed the
point at which you are tapping.
A820062_05_0208D
559
Operation
7. Open the wash--out port on the transfer tube, turn the wash-out port
lid around and close it again with the pin pointing inwards.
Trapping the Wash-Out Sponge By Turning the Wash-Out Port Lid Around
8. Switch the pump back over to reverse pumping. The wash--out

sponge will be trapped on the pin of the wash--out port lid. Then
switch the pump off.
9. Open the wash--out port lid and remove the wash--out sponge.
10. Repeat the washing out procedure, as a single reverse pumping pass
of a wash--out sponge is not sufficient.
560
A820062_05_0208D
Operation
5.8.4
Cleaning the Hopper,

Delivery Cylinder,
and S-Tube
To clean the hopper, delivery cylinder and S-tube, perform the

following steps:
Danger
In no event should you insert the water hose, the spray gun or other
objects through the grill 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.
1. Drain off the leavings onto a sheet beneath the hopper by
performing the following steps (refer to diagram below):
A. Place the Putzmeister leavings sheet beneath the hopper.
B. Open the hopper flap beneath the hopper and let the leavings
flow out of the hopper.
C. Switch the pump over to reverse pumping. This pumps the
leavings out of the delivery cylinders into the hopper and thus
out of the hopper opening.
Draining Off the Leavings Onto a Sheet Beneath the Hopper
A820062_05_0208D
561
Operation
2. Hoist away the concrete in the Putzmeister leavings sheet.
30000500
Hoisting the Concrete Away
Caution
You may only hoist a maximum of 0.5 m 3 (.65 yd3)concrete
(approximately 1200 kg or 2643 lbs) using the Putzmeister leavings
sheet.
562
A820062_05_0208D
Operation
3. As shown in the diagram below, spray out the S-tube and delivery
cylinder by performing the following steps:
A. Open the hinged elbow.
B. Allow the concrete pump to run slowly in reverse.
C. Spray the S-tube out carefully downwards from the hinged
elbow. Slowly insert the hose up to the marking as you do this
(mark the water hose using the procedure on page 5-39).
Spray Out the S-Tube and Delivery Cylinder with the Concrete Pump Running
Slowly in Reverse
D. Hold the water hose in this position, introduced as far as the

marking, for several minutes, until only clean water runs out.
This will flush out the two delivery cylinders alternately.
Insert the Water Hose into the Transfer Tube as Far as the Marking
4. Carefully spray out the hopper using a hose.

5. Hose down all components that have come into contact with
concrete.
A820062_05_0208D
563
Operation
5.8.5
Truck superstructure
and Post- Washing
Operations
Once the delivery line, hopper, delivery cylinders and transfer tube
have been washed out, you must then rinse down thoroughly all parts
of the machine that have come into contact with concrete. Concrete
that is not washed off immediately can attack the paint, especially if
aggressive concrete additives have been used. Perform truck
superstructure and post-washing operations by completing the
following steps:
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, etc. Leave the water outlet open
afterwards.
Danger of explosion
Atomized preserving agents are highly explosive. Keep away from all
sources of ignition while spraying.
Danger of poisoning
Cleaning agents, solvents or preserving agents sprayed in air can enter
the lungs and cause serious health damage. You should, therefore, always wear respiratory protection during this work.
1. Clean all seals and the seal seats. Grease the seals before replacing
them.
2. Clean the remaining parts of the machine by rinsing down with a
water hose. Then spray the metal components with an anticorrosion
agent or release agent.
3. Clean and drain the water box daily.
564
A820062_05_0208D
Operation
5.9
Teardown
5.9.1
Boom Teardown
To teardown the machine after a concrete pour and prepare it for travel,
Note
When the arm assembly is folding, the end hose cannot automatically
drop into the end hose catch brackets because of the design of the arm
assembly. Therefore, you must first move the arm into a position which
allows the end hose to drop into the end hose catch brackets.
Caution
Always observe the specified sequence for folding and unfolding the
boom. Failure to comply with the sequence may allow the crank lever
in the C hinge to compress the delivery line, adjacent hydraulic
cylinders, or other components. Retract the placing boom carefully.
Danger
Arms 3 and 4 must not be moved behind the C hinge when unfolded or
partially unfolded during the entire boom operation. In this arm
position, the rod side C cylinder hydraulic pressure is so high that the
pressure limiting valve responds and the boom will gradually slump.
There is also a risk of uncontrolled boom movements.
Before moving arm 3 to the rear, you must move arm 4 towards arm 3
until the boom tip is approximately 1 m from the C hinge.
A820062_05_0208D
565
Operation
1. As shown in the diagrams below, catch the end hose by performing

the following steps:
A. Retract arm 3 until it is vertical.
B. Unfold arm 4 completely in a single motion so that the end

hose drops into the end hose catch brackets.
566
A820062_05_0208D
Operation
Caution
You must fold arm 3 in fully before you fold arm 4 in fully, otherwise
the C hinge crank lever will press on the boom tip pipe bend.
Therefore, only fold arm 4 in fully once you have folded arm 3 in fully.
2. As shown below, fold arm 4 in so that the boom tip is
approximately 1 m from the C hinge.
3. As shown below, fold arm 3 in fully until it rests against arm 2.
A820062_05_0208D
567
Operation
4. As shown below, fold arm 4 in fully until it rests against arm 3.
Caution
Take care when folding arm 2 in that you do not damage the drivers
cab or other elements. It may be necessary to raise arm 1 higher.
5. As shown below, lower the arm assembly onto the cradle by
A. Fold arm 2 in fully until it rests against arm 1.
B. Slew the arm assembly to the boom cradle and lower it into
position.
Lowering the Arm Assembly Onto the Cradle
Note
The arms must be fully folded and lie on the supports provided.
Check that the end hose is secured for transport.
568
A820062_05_0208D
Operation
5.9.2
Outriggers Teardown
Note
The same safety and operational rules apply for retracting the
outriggers as for extending them (refer to the Outriggers Setup
section on page 523).
6. As shown in the diagram below, unlock the outrigger legs by
A. Pull out the spring pin (1).
B. Pull the lever on the snaplock upwards (2).
2
12100101
Outrigger snaplock -- Unlock the outrigger legs before you retract them or swing
them in.
7. On the radio or cable remote control, move the horn/outrigger/reset

switch to the outrigger position.
8. Raise and then retract (or swing in) the rear outriggers.
Caution
Only execute one outrigger at a time. Observe leveling bubble and
ensure that truck remains level as each outrigger is positioned.
Stability is jeopardized at a deviation from horizontal of 3_ or more.
9. Repeat Step 8 for the front outriggers.
Note
The snaplocks lock the support legs again automatically as soon as
they have reached their fully retracted position.
A820062_05_0208D
569
Operation
10. On the radio or cable remote control, move the horn/outrigger/reset

switch to the center position.
11. Secure all the outrigger leg snaplocks with spring pins.
5.9.3
Controls Teardown
12. At radio remote control transmitter (or cable remote control),
Push in emergency stop button. This should depressurize the
hydraulic system by dumping the accumulator.
Turn power switch to off position (radio only).
13. If using a cable remote control, roll up cable and store cable.
14. Store radio remote control transmitter (or cable remote control) in a
protected location, preferably in the truck cab.
15. Switch the power take-off (PTO) off by performing the following
steps:
Caution
The following points must be complied with to prevent damage when
using power take-off gearboxes:
The transmission must be in neutral when the power take-off
gearbox is switched on or off.
If the engine was shut down during pumping operations and your
truck has a manual transmission, you must depress the clutch before
starting it up again.
A. If your vehicle has a manual transmission, perform these steps:
Push in clutch pedal (clutch disengaged).
Place truck transmission in neutral
Let clutch pedal out (clutch engaged).
B. If your vehicle has an automatic transmission, shift selector
from D (Drive) toN (Neutral).
C. Position concrete pump PTO switch (located on right side of
drivers seat) to DRIVE position (PTO disengaged).
D. Verify that green PUMP light goes out.
E. Release parking brake.
570
A820062_05_0208D
Operation
F. If your vehicle has an automatic transmission, shift selector to

D (Drive). Display indicates 1 signifying that the truck
transmission is in 1st gear.
16. Secure the end hose and the accessories against falling from the
truck.
17. Confirm that the accumulator is depressurized by looking at the
accumulator pressure gauge.
A820062_05_0208D
571
Operation
5.10
Pumping Concrete
with the Emergency
Stroke Kit
To pump concrete with the Emergency Stroke Kit (P/N 134931),

Danger
THE EMERGENCY STROKE KIT SHOULD ONLY BE USED IN
AN EMERGENCY CONDITION. THE EMERGENCY STOP
(E-STOP) BUTTON DOES NOT WORK WHEN USING THE
EMERGENCY STROKE KIT.
1. Stop truck engine and verify that shift circuit pressure is at zero.
2. Disconnect pump harness from the following valves on the compact block:
Main control valve (2 connections)
Accumulator dump valve (1 connection)
3. Connect Emergency Stroke Kit wiring harness to three connections disconnected in
Step 2 and battery (refer to diagram below):
Battery
20 Amp Fuse
Toggle Switch
ON
OFF
Main
Control
Accum.Dump
Emergency Stroke Kit (Connected Between Battery and Compact Block)
4. Start truck engine.

5. Ensure that truck engine RPM is greater than 900 RPM.
6. Use toggle switch on Emergency Stroke Kit wiring harness to shift drive cylinders at
end of each stroke.
7. During an emergency condition or when job has been completed, stop truck engine.
572
A820062_05_0208D
Maintenance
In this section 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.
We would like to emphasize that all prescribed checks, inspections and
preventative maintenance work must be conscientiously carried out.
Otherwise, we will refuse to accept any liability or to honor the
warranty. Should you ever be in any doubt, our After Sales Department
is always ready to give you advice and assistance.
This topic:
6.1
Maintenance Intervals
62
6.2
General Tightening Torques
64
6.3
Functional Fluids
67
6.4
Recommended Lubricants
610
6.5
WK00_001: Visual Checks
615
6.6
WK03_001: Changing the Hydraulic Fluid
617
6.7
WK03_002: Function Checks
623
6.8
WK03_006: Performing Maintenance on the Accumulator
625
6.9
WK04_001: Filter Change
631
6.10 WK04_002: Hoses
639
6.11 WK04_005: Vacuum Meter
643
6.12 WK06_009: Change of Delivery Piston with KEP
645
6.13 WK07_001: Lubricating the S Transfer Tube
655
NO TAG
S Transfer Tube
A820062_06_0412
Starts on page:
WK07_011:
NO TAG
6.14 WK10_007: Measuring the Wall Thickness
681
6.15 WK20_044: Lubricating the M 36Z Placing Boom
687
6.16 WK21_011: Lubricating the Boom Pedestal (TRDI 70)
689
6.17 WK25_001: Replacing the Delivery Line
691
61
Maintenance
6.1
Maintenance
Intervals
The following table shows the intervals for the various maintenance
tasks. The associated maintenance cards can be found further on in this
section.
Note
Have the initial After Sales service after 100 hours of operation carried
out by a Putzmeister After Sales service engineer in accordance with
the enclosed inspection booklet. The machine operator responsible for
the machine should be present for this service.
Assembly
General
Action
every ... hours of operation

daily
Lubricate truck superstructure
Visual and function check on all safety

equipment
62
500
other
1000 intervals
weekly
Visual inspection of electrical cabling
Check hydraulic fluid level
Drain off condensed water
Visual check of the lines

(damage/leaks)
Full fluid change (after fluid analysis)
Clean fluid sump
Check contamination indicator on the

filters
Water tank
250
as required
Check hydraulic cylinder for tightness

(visual inspection)
Fluid filter
100
Check threaded unions against torque

table
Inspection by subject expert
H dr lic system
Hydraulic
s stem
50
annually
monthly
D
Replace boom filter element
as required
Replace intake filter element
as required
Check water level
A820062_06_0412
Maintenance
Assembly
Transmission
Boom pedestal
Transfer tube
every ... hours of operation
Action
daily
50
100
250
Full oil change splitter box
Full oil change agitator gearbox
Full oil change slewing gear

transmission
Delivery piston
other
1000 intervals
Condensed water slewing gear transmission
Check slewing ring bolts (if applicable)
Wear check
Check and adjust sealing gap
Check tightening torque of bolts

Deli er line
Delivery
500
Coupling safety clips
Check wall thickness
Check threaded unions and securing

wire
Check wear on delivery pistons
weekly
Parts in contact with concrete
Wear check
Centralized lubrication system
Check grease level
Check oil level
Compressor
Full oil change
Clean air intake filter
Check threaded unions
Universally jointed shafts

(in normal operating conditions)
Lubricate
Universally jointed shafts

(in extreme operating conditions)
Lubricate
annually
D
D
Truck engine
Truck transmission
A820062_06_0412
In accordance
ccord nce with
ith the truck
tr ck m
manufacturers
n f ct rers m
maintenance
inten nce specific
specifications
tions
63
Maintenance
6.2
General Tightening
Torques
Tightening torques depend on bolt grade, thread friction and bolt 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 sections of the Operating Instructions or in spare parts sheets.
Caution
You must always use bolts of the same size and grade when you have to
replace bolts. Bolts with adhesive in the locking threads and self--locking
nuts must always be replaced after removal.
The tables below give the maximum tightening torques Md in Nm for a

friction factor tot. = 0.14, for a lightly--oiled or lightly--greased thread.
Note
All tightening torques are multiplied by a factor of 1.1 for bolts with
cement in the thread.
64
A820062_06_0412
Maintenance
Set screws -- metric triangular thread DIN 13, Part 13

Dimensions Tightening torque
[mm]
Md [Nm]
M
SW
8.8
10.9 12.9
M 4
10000900
SW = Width across flats

X.X = G
Grade 8.8, 10.9, 12.9
Tightening torque
Md [Ft-Lb]
8.8
10.9 12.9
3.0
4.4
5.1
2.22
3.26
3.77
M 5
5.9
8.7
10
4.37
6.44
7.4
M 6
10
10
15
18
7.4
11.1
13.3
M 8
13
25
36
43
18.5
26.6
31.8
M 10
17
49
72
84
36.3
53.3
62.2
M 12
19
85
125
145
62.9
92.5
107
M 14
22
135
200
235
99.9
148
174
M 16
24
210
310
365
155
229
270
M 18
27
300
430
500
222
318
370
M 20
30
425
610
710
315
451
525
M 22
32
580
820
960
429
607
710
M 24
36
730
1050
1220
540
777
903
M 27
41
1100
1550
1800
814
1147
1332
M 30
46
1450
2100
2450
1073
1554
1813
Set screws -- metric precision thread DIN 13, Part 13

Dimensions
Tightening torque Tightening torque
[mm]
Md [Nm]
Md [Ft-Lb]
M
SW 8.8 10.9 12.9 8.8 10.9 12.9
10000900
SW = Width across flats

X.X = G
Grade 8.8, 10.9, 12.9
A820062_06_0412
M 81
13
27
39
46
19.98
28.86
34.0
M 10 1.25
17
52
76
90
38.48
56.24
66.6
M 12 1.25
19
93
135
160
68.82
99.9
118.4
M 12 1.5
19
89
130
155
65.86
96.2
114.7
M 14 1.5
22
145
215
255
107.3
159.1
188.7
M 16 1.5
24
225
330
390
166.5
244.2
288.6
M 18 1.5
27
340
485
570
251.6
358.9
421.8
M 20 1.5
30
475
680
790
351.5
503.2
584.6
M 22 1.5
32
630
900
1050
466.2
666
777
M 24 2
36
800
1150
1350
592
851
999
M 27 2
41
1150
1650
1950
851
1221
1443
M 30 2
46
1650
2350
2750
1221
1739
2035
65
Maintenance
6.2.1
Flared Screwed
Joint, Reassembly
Every time the joint has been undone, the union nut must be tightened
securely, without the use of excessive force.
Flared screwed joints

External
diameter/
Type
Md [Nm]
Md
[Ft--Lb]
External
diameter/
Type
Md [Nm]
Md
[Ft--Lb]
20
14.8
18
120
88.8
40
29.6
20
250
185
55
40.7
25
400
296
80
59.2
30
500
370
15
70
51.8
38
800
592
16
130
96.2
12
Note
Hold threaded union spigot fast against turning with wrench.
10400100
Tightening flared screwed joint
6.2.2
66
Profiled Ring Joint,

Reassembly
Every time the joint has been undone, the union nut should be tightened
again without excessive force to ensure that the joint is tight.
A820062_06_0412
Maintenance
6.3
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.
6.3.1
Hydraulic Fluid
The hydraulic system is filled with:

-- mineral hydraulic fluid (HV) 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 with different characteristics (i.e. do not mix
biologically degradable hydraulic fluid with mineral hydraulic fluids
etc.).
Note
Please only use a hydraulic fluid complying with the classification and
requirements standards specified in the lubricant recommendation 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 concerned.
When hydraulic fluids of different viscosity grades are mixed, the new
viscosity is determined by the mix ratio. Loss of quality is possible 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 10 -- 15% of the old
hydraulic fluid remains in the system (in cylinders, pumps, lines, etc).
Take note of VDMAs changeover guidelines and manufacturers
instructions if you are changing over your fluid. Please contact the
manufacturers concerned if you have any queries regarding the
suitability and miscibility of hydraulic fluids.
A820062_06_0412
67
Maintenance
6.3.2
Oil for the Power

Take- Off (PTO),
Rotor and Agitator
Gearboxes
The power take--off and agitator gearboxes are filled with an API GL4
transmission oil of viscosity grade SAE 90.
6.3.3
Manual Lubrication
Use a multipurpose lithium soap base grease for lubrication.

Marking in accordance with DIN 51 502: K2K--30, NLGI Class 2.
6.3.4
Centralized
Lubrication System
Fill the centralized lubrication system with a multipurpose lithium soap

base grease.
Marking in accordance with DIN 51 502: K1K--30, NLGI Class 1.
Low temperature
greases
We recommend grease marked K E 2G--60 in accordance with

DIN 51502, NLGI Class 2 in a deviation from the lubricants table if
you wish to use a low temperature grease in the centralized lubrication
system under conditions of extreme cold.
Truck Engine Oil and

Transmission Oil
The engine and the truck transmission are filled by the truck
manufacturer. Maintenance only in accordance with the truck
manufacturers specifications.
6.3.5
68
Use only high quality transmission oil matching this specification for
topping up or for a full oil change (observe the manufacturers
information).
A820062_06_0412
Maintenance
6.3.6
Level of Contaminant
Level of contaminant 18/14 in accordance with ISO 4406 is specified for

lubrication and the hydraulic system. You can find the level of
contaminant of the original filling from the report of results on the
machine card.
6.3.7
Lubricant Analysis
Please consult the Putzmeister After Sales Department should you

discover that the functioning of your machine is impaired with one of
the lubricants or hydraulic fluids used. We will carry out a lubricant
analysis to determine the cause.
6.3.8
Storage of
Lubricants
Do not store oils and greases in the open air. Water may be absorbed
through the bung hole in the event of changes in the exposure to the
weather.
Only store the barrels lying on their side and supported on timber
blocks, with the bung hole facing upwards.
You must carefully collect all functional fluids, e.g. used oil (including biologically degradable oils), filters and auxiliary materials and dispose 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.
A820062_06_0412
69
Maintenance
6.4
Recommended
Lubricants
We have listed the suitable lubricants in the tables on the next page.
Putzmeister accepts no liability for the quality of the lubricants listed or
for changes in quality made by the lubricant producer without changing
the grade designation.
Note
Please use only Putzmeister hydraulic fluid, part 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 hydraulic fluid in the works (HFC as specified in the 7th Luxembourg
Report).
Please use only Putzmeister hydraulic fluid, part 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 Multi-grade 68 (e.g.,
at higher ambient temperatures).
The proportion of residual fluid must not be greater than 2% after a
fluid change from HV 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 be carried
out no later than 6 months after the machine is commissioned. It should
also be noted, at this point, that all filters must be changed after 50
hours of operation, since deposits may be dissolved and transported to
the filters by the new fluid.
610
A820062_06_0412
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 temperature of the hydraulic fluid (Multi-grade 68) has risen above 10 _C.
The ideal temperature for the hydraulic fluid (HV or HEES,
Multi-grade 68) is between 40 _C and 70 _C.
Danger
Never mix hydraulic fluids of different types, ie do not mix biologically
degradable hydraulic fluids with mineral hydraulic fluids etc.
A820062_06_0412
611
Maintenance
6.4.1
Hydraulic Fluids
Type
Class
Classification
DIN
ISO
Requirement
DIN
ISO
VDMA
Other
Viscosities
DIN
ISO
2
mm /s ISO VG
Use
Petroleum
51524 Part 3
6743 Part 4
24318
24568
24317 / 24320
7th Luxembourg Report
51519
3448
46
68
46
30_F to 210_F
(-10_C to +90_C)
15 _F to 90_F
(-10_C to +90_C)
--4_F to 140_F
(--20_C to +60_C)
Multi-grade
biodegrades quickly
non--readily flammable
A026533
239693.000
BECHEM HYDROSTAR
HEP 46
239879.002
FUCHS HYDROTHERM
46 M
24569
24314
Manufacturer
Benz Oil
Changeover guidelines
VDMA
Oils and Greases
Marking in acc.
with DIN 51 502
Requirements
standard
Characteristics
612
Aqueous solutions
HFC
51502
6743/4
Particular characteristics
Initial filling
Part number
6.4.2
Synthetic ester
HEES
Engine oil
Transmission oil*
Greasing
(manual)
Centralized
lubrication
system
HD
HYP
K2K--30
K1K--30
API CH--4/SJ
API GL4
DIN 51 825
DIN 51 825
mineral
mineral, lithium soap
A820062_06_0412
Maintenance
Viscosity grade,
NLGI Class
SAE 15W--40
DIN 51511
SAE 90
DIN 51512
Standard
SAE 80
DIN 51512
Winter
NLGI Class 2
DIN 51818
NLGI Class 1
DIN 51818
Part number
000173.005
000101.006
A026511
360001.008
* The transmission oil for rotor pumps is listed separately.
A820062_06_0412
613
Maintenance
614
A820062_06_0412
Maintenance Card
00--001
Page 1 of 2
6.5
Visual Checks
This maintenance card describes visual checks that you must carry out
before commencing any maintenance work. You will find the service
intervals in the maintenance summary at the start of this chapter.
Filter change
Hoses
No special tools required.
Danger
Inspect the electrical cables particularly closely and carefully. There is
a danger of overvoltages 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_9411GB
615
Maintenance Card
00--001
Page 2 of 2
General
Electrical system
Hydraulic system
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.
You must have any damage found in the electrical system 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.
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 vacuum filters must be replaced if the displays are in the red range.
Maintenance card: Filter change
"
Check the contamination indicators on the boom filters. The filters are in order if the red button remains depressed. The filter
must be replaced if the red button pops out.
"
Check the oil cooler for contamination and deposits.
"
Check all hydraulic hoses for leaks.

Maintenance card: Hoses
"
Check all hydraulic threaded unions for tightness and leaks.

616
WK00_001_9411GB
Maintenance card
01019
Page 1 of 6
01 - 019
G64 C transfer gearbox
This maintenance card describes changing the oil and checking the
oil level in the transfer gearbox.
No further maintenance cards required.
Caution
The transfer gearbox must never be shifted when under load. Only
shift the transfer gearbox when the Cardan shaft is stationary.
Check that the expirator screws are clean and operating correctly
each time that the oil in the transfer gearbox is changed. If necessary,
clean or replace the expirator screws.
The transfer gearbox must never be operated if an expirator screw is
missing or defective. Otherwise, leaks may occur due to an increase
in pressure.
This may then cause damage to the transfer gearbox.
Note
The transfer gearbox lubrication circuit is divided into the following
areas:
Oil circuit A" lubricates the gearbox.
Oil circuit B" lubricates the connection of the hydraulic pumps.
Check the oil level in oil circuit B" each time the oil is changed in the
transfer gearbox and top up with gearbox oil, if necessary. It is not
necessary to change the oil in oil circuit B".
wk01_019_0807en
1
Maintenance card
01019
Page 2 of 6
Oil change in oil circuit A
This section describes how to change the transfer gearbox oil in oil
circuit A".
Note
The oil change intervals can be found in the maintenance summary
at the start of this chapter.
Information concerning oil specification and filling capacity is con
tained in the spare parts sheet. It is not permissible to use oils other
than those specified without first consulting with Putzmeister after
sales service (APS department).
Information concerning parts required and tightening torques can be
found in the spare parts sheet.
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
disposal regulations must be observed for these materials.
Note
Before changing the oil, carry out the following procedures:
Engage the power takeoff and allow the transfer gearbox to
warm up.
Disengage the power takeoff.
Allow the oil to settle for a while, then start the oil change.
2
wk01_019_0807en
Maintenance card
01019
Page 3 of 6
The gearbox oil can be added via the bore hole of expirator
screw A" (1). The oil level in the gearbox must reach as far as
oil level check screw A" (2).
OIL
3
wk01_019_0807en 1
No. 0
1
2
3
wk01_019_0807en
Designation
Expirator screw A"
Oil level check screw A"
Oil drain plug
"
Unscrew expirator screw A" (1) and oil level check screw A" (2).
In the process, make sure that no foreign matter enters the
gearbox through the open bore holes.
"
Drain the gearbox oil via the bore hole of the oil drain plug (3).
"
Clean all screws/plugs that were removed.
"
After the oil has drained, replace the sealing ring of the oil
drain plug (3) and screw the plug back into place using the
specified tightening torque.
3
Maintenance card
01019
Page 4 of 6
Checking the oil level

in oil circuit B
"
Add the gearbox oil via the bore hole of expirator screw A" (1).
The oil level must reach as far as the bore hole of oil level
check screw A" (2).
"
After approx. 10 minutes, check the oil level and correct,

if necessary.
"
Replace the sealing rings of expirator screw A" (1) and oil
level check screw A" (2) and refit these screws using the
specified tightening torques.
This section describes how to check the transfer gearbox oil level in
oil circuit B". The oil level in the oil chamber must reach as far as oil
level check screw B" (5). The gearbox oil can be added via the bore
hole of expirator screw B" (4).
OIL
wk01_019_0807en 2
No. 0
4
5
4
Designation
Expirator screw B"
Oil level check screw B"
wk01_019_0807en
Maintenance card
01019
Page 5 of 6
wk01_019_0807en
"
Unscrew expirator screw B" (4) and oil level check screw B" (5).
In the process, make sure that no foreign matter enters the
gearbox through the open bore holes.
"
Clean all screws/plugs that were removed.
"
Check the oil level in the oil chamber. The oil level must reach
as far as the bore hole of oil level check screw B (5).
"
If required, add the gearbox oil via the bore hole of expirator
screw B" (4).
"
Replace the sealing rings of expirator screw B" (4) and oil
level check screw B" (5) and refit these screws using the
specified tightening torques.
5
Maintenance card
01019
Page 6 of 6
6
wk01_019_0807en
Maintenance Card
03--001
Page 1 of 6
6.6
Changing the
Hydraulic Fluid
This maintenance card describes how to carry out a full oil change on
the hydraulic system. You will find the service intervals in the
maintenance summary at the start of this section.
Function checks
Filter change
Hoses
Note
Cleanliness is of the greatest possible importance in the maintenance
of hydraulic systems. You must make it impossible for dirt or other
impurities to enter the system. Even small particles may cause valves to
be scored, pumps to seize and choke and control bores to become
blocked.
Hydraulic fluid drums must stand for some time before the fluid is
taken from them. Never roll the barrels to where you will be drawing
off the fluid. Clean bungs, filler caps and their surroundings before
opening them.
If possible, you should use a filler unit to fill up the hydraulic system.
Never leave the tank lid open longer than necessary.
WK03_001_9909
617
Maintenance Card
03--001
Page 2 of 6
Preparation
The following tasks must be carried out before starting the full fluid
change:
"
Switch off the remote control.
"
Switch the hydraulic pumps off.
"
Reduce fluid pressure completely.
"
Check the contamination indicator on the vent filter of the fluid

reservoir. You must replace the filter element for the vent filter
when the red check ring is visible in the inspection glass.
10401903
618
Red check ring in the inspection glass
WK03_001_9909
Maintenance Card
03--001
Page 3 of 6
Danger
The accumulator pressure in pressurized systems must be released.
Confirm via gauge.
"
Switch the drive engine off.
"
Secure the system against unauthorized starting if you have

any keyed switches, remove the key and disconnect the supply
voltage.
"
Secure your working area and fix notices to the blocked controls
and setting devices.
Changing the fluid
10300400
Draining off the fluid
You must make sure you collect the old hydraulic fluid and dispose of it
in accordance with the regulations. Biologically degradable hydraulic
fluids must also be disposed of separately from other waste, just like
mineral hydraulic fluids!
"
WK03_001_9909
Remove a hose from the hydraulic system tank and drain off the
fluid.
619
Maintenance Card
03--001
Page 4 of 6
"
Then disconnect all hoses from the tank.
Note
Mark the hoses and their connection points for re--assembly.
10400300
Marking the hoses
"
Wipe out all the openings with a lint--free cloth. Wipe as far into
the tank as possible when doing this. You should also remember
that there may also be separate apertures intended for tank cleaning.
"
Remove all filter inserts.

"
Change all filters and refit the filter elements.
"
Replace any defective hoses.

Dispose of the old filter inserts in accordance with the regulations in
force.
620
WK03_001_9909
Maintenance Card
03--001
Page 5 of 6
10300500
Filling the tank
"
Fill the tank with new fluid.
Note
Only fill the tank through the mesh in the filler inlet. Fill up the tank up
to the Maximum marking after bleeding and a test run. Use only the
hydraulic fluids specified in the lubrication recommendations.
"
Remove the dirt deposits from the oil cooler.
"
Check all screwed joints and tighten where necessary. Check all
flared screwed joints.
"
Check the electrical connections.
"
Carry out all function checks.

Maintenance card: Function checks
WK03_001_9909
"
Bleed hydraulic system.
"
Carry out several test runs.
"
Refit all the safety equipment, markings and notices you have
removed.
621
Maintenance Card
03--001
Page 6 of 6
622
WK03_001_9909
Maintenance Card
03--002
Page 1 of 2
6.7
Function Checks
This maintenance card describes the inspection of machine functions.

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.

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.
WK03_002_9411GB
"
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 Measurements sheet.
"
Check the proper functioning of the pressure--relief valves in the

high pressure circuit and the pressure accumulator.
623
Maintenance Card
03--002
Page 2 of 2
624
WK03_002_9411GB
Maintenance Card
03--006
Page 1 of 6
6.8
Performing
Maintenance on the
Accumulator
This maintenance card describes how to check the accumulator

pre--charge pressure. You should also take notice of any requirements
valid in the country of use or specified by the operator.
Charging and Gauging Kit (Putzmeister #311803)

Gas Valve Core Tool
Spanner Wrenches
Bladder Pull Rod
Sockets -- 27 mm, 36 mm
Blunt Flathead Screwdriver
Soft Faced Hammer
Torque Wrenches
1
3
2
5
4
Charging and Gauging Kit
1
2
3
4
5
WK03_006_9909
T-handle
Manual bleed valve
Check valve
Cap nut
Charging hose, including cap screw connections
625
Maintenance Card
03--006
Page 2 of 6
Danger of explosion
USE ONLY DRY NITROGEN TO FILL THE ACCUMULATOR.
THERE IS A DANGER OF EXPLOSION IF COMPRESSED AIR,
OXYGEN OR OTHER GASES ARE USED.
Note
Check the accumulator pre--charge pressure once the hydraulic fluid
has warmed up to its operating temperature of 122_F (50 _C) to
158_F (70 _C).
The setpoint value for the accumulator pre--charge pressure may be
found on the hydraulic schematic (item 120). The actual value you
measure may not be more than 15% less than the setpoint value
specified.
Warning
Adhere to the following safety regulations when performing
maintenance on the accumulator:
The hydraulic accumulator is a pressurized vessel and only qualified
technicians should perform the necessary repairs.
The fluid must always be drained completely from the accumulator
before performing any work.
626
WK03_006_9909
Maintenance Card
03--006
Page 3 of 6
10
1
11
2
12
10
11
12
13
5
6
7
8
14
6
7
8
9
15
16
Accumulator
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
WK03_006_9909
Gas valve core

Lock nut
Shell
Bladder
Anti-extrusion ring
Flat ring
O--ring
Spacer ring
Locknut
Valve protection cap
Valve seal cap
O--ring
Name plate
Fluid port
Vent screw
Seal ring
627
Maintenance Card
03--006
Page 4 of 6
6.8.1
Checking
Accumulator
Pre-Charge Pressure
To check accumulator pre-charge pressure, perform the following

steps:
Note
The proper gas pre--charge pressure (1320 PSI or 90 bar) is set at the
factory. It is suggested that the pressure be rechecked approximately
3--4 months after placing unit in service and every 12 months
thereafter.
Danger
BEFORE CHECKING THE PRE- CHARGE PRESSURE, BE
SURE MACHINE IS SHUT DOWN AND ALL HYDRAULIC
PRESSURE AND FLUID IN ACCUMULATOR HAS BEEN
RELIEVED.
1. Unscrew valve protection cap (#10) and valve seal hex cap (#11).
Be careful not to damage O--ring (#12) when removing cap.
2. To connect gauging unit to accumulator, perform the following
steps:
Turn T-handle counterclockwise until resistance is felt.
Close manual bleed valve, hand tight.
Connect gauging unit to accumulator by screwing cap nut onto
gas valve, hand tight.
3. After gauging unit has been installed, turn T-handle clockwise a
maximum of 3 full turns from full counterclockwise position.
4. If gauge does not indicate 1320 PSI (90 bar), perform appropriate
procedure to increase or decrease accumulator pressure:
If pressure reading is . . .
< 1320 PSI (90 bar)
> 1320 PSI (90 bar)
Then . . .
Increase pressure
Decrease pressure
By performing this procedure . . .

Increasing Accumulator Pressure
Decreasing Accumulator Pressure
5. If gauge indicates proper pre-charge pressure, remove charging and

gauging unit by performing the following steps:
Turn T--handle counterclockwise until resistance is felt to close
gas valve.
Open manual bleed valve to relieve pressure in gauging unit.
Disconnect gauging unit by unscrewing cap from gas valve.
Re-install valve seal hex cap and tighten to 20 lb. ft. (27 Nm).
Re-install valve protection cap, hand tight.
628
WK03_006_9909
Maintenance Card
03--006
Page 5 of 6
6.8.2
Decreasing
Accumulator
Pressure
To decrease pressure in accumulator, perform the following steps:

1. Install charging and gauging unit as per Steps 1--3 of Checking
Accumulator Pre-Charge Pressure procedure on page 628.
2. Carefully open manual bleed valve, allowing gas pre--charge
pressure to release slowly.
3. Monitor gauge until desired gas pressure is reached.
4. Close manual bleed valve and allow pressure to stabilize.
5. After 5--10 minutes, recheck pressure and adjust accordingly.
6. When correct pressure is reached, remove charging and gauging
unit by performing the following steps:
gas valve.
Disconnect gauging unit by unscrewing cap from gas valve.
6.8.3
Increasing
Accumulator
Pressure
To increase accumulator pressure to specified pressure (per hydraulic

schematic), perform the following steps:
1. Install charging and gauging unit as per Steps 1--3 of Checking
Accumulator Pre-Charge Pressure procedure on page 628.
2. Allow 5--10 minutes for the gas temperature to stabilize.
3. Turn T-handle clockwise until gauge begins to deflect, then turn it
another full turn.
Danger
ONLY USE DRY NITROGEN GAS. NEVER USE OXYGEN OR
AIR BECAUSE IT COULD CAUSE AN EXPLOSION.
Caution
It is recommended that the commercial nitrogen bottle be equipped
with a regulator to adjust pressure. Full pressure may damage the
gauge.
WK03_006_9909
629
Maintenance Card
03--006
Page 6 of 6
4. Connect charging hose to cap screw adapter and to nitrogen bottle

discharge.
5. Purge air in hose so you charge only with nitrogen.
6. Open shut--off valve on nitrogen bottle and slowly fill accumulator
with dry nitrogen gas. Charging too quickly may damage the
accumulator.
Note
The gauge on the gauging unit registers the line pressure and not
necessarily the accumulator pressure while charging.
7. Check accumulator pressure as follows:
Close shut-off valve on nitrogen bottle.
Allow gas temperature and pressure to stabilize.
Check accumulator pressure.
8. Fill or release pressure as required until required pressure is
reached.
9. When correct pressure is reached, remove nitrogen bottle and
gauging unit by performing the following steps:
Close shut--off valve on nitrogen bottle.
gas valve.
Disconnect charging hose and remove gauging unit from
accumulator.
6.8.4
630
Replacing
Accumulator Bladder
To replace the accumulator bladder, take to a qualified hydraulic shop.
WK03_006_9909
Maintenance Card
04--001
Page 1 of 8
6.9
Filter Change
This maintenance card describes how to change all the filters in the
hydraulic system. You will find the service intervals in the maintenance
summary at the start of this section.
Note
Cleanliness is of the greatest possible importance in the maintenance
of hydraulic systems. You must make it impossible for dirt or other
impurities to enter the system. Even small particles may cause valves to
be scored, pumps to seize and choke and control bores to become
blocked.
Hydraulic fluid drums must stand for some time before the fluid is
taken from them. Never roll the barrels to where you will be drawing
off the fluid. Clean bungs, filler caps and their surroundings before
opening them.
If possible, you should use a filler unit to fill up the hydraulic system.
Never leave the tank lid open longer than necessary.
WK04_001_9605GB
631
Maintenance Card
04--001
Page 2 of 8
Preparation
The following tasks must be carried out before starting the filter
change:
"
Switch off the remote control.
"
Switch the hydraulic pumps off.
"
Switch the drive engine off.
"
Reduce fluid pressure to zero.
Danger
The accumulator pressure in pressurized systems must be dumped.
"
Secure the system against unauthorized starting if you have

any keyed switches, remove the key and disconnect the supply
voltage.
"
Secure your working area and fix notices to the blocked controls
and setting devices.
Note
You must never attempt to clean Micronic filter elements. You must
always replace them.
Before you fit the new filters, you must check all O--rings and other
sealing elements of the filter elements and replace them if damaged.
Dispose of the old filter elements in accordance with the regulations in
force.
632
WK04_001_9605GB
Maintenance Card
04--001
Page 3 of 8
Vacuum filter
Replace the vacuum filter elements once the indications on the vacuum
meter are in the red zone. The procedure is as follows:
"
Place a container under the drain cock (1) to allow you to catch
the escaping hydraulic fluid.
1
10400201
Drain cock
"
Unscrew the hexagon nuts to the stop.
"
Withdraw the filter element to the stop without turning it.
Note
An isolating valve interrupts the fluid supply automatically.
"
Open the upper stopper to provide an air supply.
"
Open the drain cock (1) and allow the hydraulic fluid to run out
of the filter casing.
You must dispose of the escaping hydraulic fluid in accordance with the
regulations in force.
WK04_001_9605GB
633
Maintenance Card
04--001
Page 4 of 8
"
Turn the hooked lid to the left and withdraw the filter element.
"
Unscrew the hexagon bolt from the bar magnet.
"
Turn the filter element to the left and withdraw it from the bar
magnet.
"
Wipe the bar magnet lengthways with a clean cloth.
"
Fit a new filter element and replace the hexagon bolt.
Caution
Filter elements freely available on the market have too low a flow rate.
You must, therefore, only ever use original Putzmeister filter elements
in order to prevent damage to the machine.
634
WK04_001_9605GB
Maintenance Card
04--001
Page 5 of 8
"
Check and, if necessary, set the filter element to the correction

dimension of 346 mm 0.5. The correction dimension is measured from the lower edge of the cover to the tip of the element.
10400401
Correction dimension
Caution
The filtering process causes dirt particles to accumulate in the filter
casing. You must, therefore, clean the filter casing thoroughly before
fitting the new filter element, as otherwise the new filter element will
become clogged very quickly.
WK04_001_9605GB
"
Thoroughly clean the filter casing with a clean cloth.
"
Install a new filter element. The installation procedure is the reverse of the procedure for removing a filter element.
635
Maintenance Card
04--001
Page 6 of 8
Boom filter
Replace the boom filter element if the red button pops out again after
being pressed in at operating temperature.
Checking
10400601
Checking and replacing boom filter
"
Bring the machine up to operating temperature (> 50 C).
"
Set the maximum output.
"
Press the red button on the boom filter.
Note
The filter is OK if the red button remains depressed.
The filter element must be replaced if the red button pops out again.
636
WK04_001_9605GB
Maintenance Card
04--001
Page 7 of 8
Replacing
10400500
Replacing the boom filter
"
Undo the filter casing and replace the filter element.
Caution
The filtering process causes dirt particles to accumulate in the filter
casing. You must, therefore, clean the filter casing thoroughly before
fitting the new filter element, as otherwise the new filter element will
become clogged very quickly.
"
Thoroughly clean the filter casing with a clean cloth.
"
Install a new filter element.
Note
Check the level of the contamination indicator. Always replace the
protective cover to the contamination indicator after checking.
WK04_001_9605GB
637
Maintenance Card
04--001
Page 8 of 8
Hydraulic fluid tank

vent filter
Replace the ventilation filter element if the red check ring is visible in
the inspection glass.
Checking
10401903
Red check ring in the inspection glass
Replacing
1
10401902
638
Cover
"
Remove the cover from the filter casing.
"
Replace the filter element.
"
Replace the cover.
WK04_001_9605GB
Maintenance Card
04--002
Page 1 of 4
6.10
Hoses
This maintenance card describes how to check and replace the

hydraulic hoses. You will find the service intervals in the maintenance
summary at the start of this chapter.
Note
Check all hoses (including hose fittings) with the machine running.
You must replace the hoses at the slightest sign of damage or even mere
indications of threatened damage.
Leaking hose
10400800
Check hydraulic hoses
Dark and moist patches on the fitting are external signs of incipient
damage. Check:
-- the hoses for kinks, cracks or a porous surface, and
-- whether the hoses have been laid without restrictions.
Note
Beware of strong sunlight, the action of heat and the effects of
chemicals.
WK04_002_0106
639
Maintenance Card
04--002
Page 2 of 4
10400100
Tighten until there is a clearly perceptible increase in

force
"
Check whether the flared screwed joints are tight.
Note
You may only tighten leaking flared screwed joints with the permitted
torque. Tighten the joint 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.

External
diameter/
Type
Md
[Ft--Lb]
External
diameter/
Type
Md [Nm]
Md
[Ft--Lb]
20
14.8
18
120
88.8
40
29.6
20
250
185
55
40.7
25
400
296
80
59.2
30
500
370
15
70
51.8
38
800
592
16
130
96.2
12
640
Md [Nm]
WK04_002_0106
Maintenance Card
04--002
Page 3 of 4
Replacing hoses
The procedure for replacing hoses is as follows:

"
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 unions.
"
Close the connection points with a plug immediately after you

have removed the old hoses. No dirt may enter the hydraulic circuit and the hydraulic circuit must not run empty.
Danger
Hoses may not be more than six years old, including a storage period
of two years. Take note of the date of manufacture on the hoses.
"
Keep the hoses free from dirt.
"
Thoroughly clean the inside of the hose.
"
Fit the hoses to be free from bends or chafe points.
"
Bleed the hydraulic system.
"
Carry out a test run and inspect all hoses again after fitting new
hoses.
Catch escaping fluid in a container and dispose of in an environmentally friendly manner.
WK04_002_0106
641
Maintenance Card
04--002
Page 4 of 4
642
WK04_002_0106
Maintenance Card
04--005
Page 1 of 2
6.11
Vacuum Meter
This maintenance card describes how to replace the vacuum meter and
how to remove the packing piece. You will find the service intervals in
the maintenance summary at the start of this section.
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_9909
643
Maintenance Card
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
"
644
Open the vent by either cutting off the tip of the packing piece or
piercing the rubber stopper, depending on the design. Do not
remove the rubber plug from the gauge.
WK04_005_9909
Maintenance Card
06--009
Page 1 of 10
6.12
Change of Delivery
Piston with KEP
This maintenance card describes how to change the delivery pistons on

machines with KEP. KEP (Piston end--of--travel positioning) is the ball
valve fitted in the stroke equalization line of drive cylinder II (on the
left looking in the direction of travel). You will find the maintenance
intervals in the maintenance summary at the start of this chapter.
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 regulations.
Danger
Secure the working area. Affix warning notices to the blocked control
and setting devices. Never place your hands in or around the water
box when the engine of the machine is running, since this could result
in severe personal injury or death.
WK06_009_9909
645
Maintenance Card
06--009
Page 2 of 10
When replacing the delivery pistons you will have to start and stop the
machine a number of times. The operations necessary for this are
described below and must be carried out conscientiously. Carry out all
machine functions from the cable control.
Shutting down the
machine
The procedure for shutting down the machine is as follows

"
Switch the engine off.
"
Press in the EMERGENCY SHUT--DOWN button.
"
Dump the pressures completely.
Danger
Dump the accumulator pressure completely in systems with pressure
accumulators.
Starting up the machine
646
The procedure for starting up the machine is as follows:

"
Unlock the EMERGENCY SHUT--DOWN button and sound the

horn.
"
Switch the engine on.
WK06_009_9909
Maintenance Card
06--009
Page 3 of 10
Block drive cylinder I

in the end position
Block drive cylinder II

in the end position
Drive cylinder I is located on the right looking in the direction of

travel. You may block drive cylinder I in the end position to make it
easier to remove the delivery piston. This is done as follows:
"
Press the Stroke change--over button when the concrete pump

is running and hold it down until the concrete pump switches off.
"
You must switch the concrete pump off when the drive cylinders
have reached the end position. Then you can release the Stroke
change--over button.
Drive cylinder II is located on the left looking in the direction of travel.

The stroke equalization line incorporates a ball valve (KEP) which is
fitted open (markings parallel to the line) in the works and is locked
against rotation.
KEP
20202301
The works fits the KEP valve in the open state
WK06_009_9909
647
Maintenance Card
06--009
Page 4 of 10
You may block drive cylinder II in the end position to make it easier to
remove the delivery pistons. This is done as follows:
20202302
1
2
648
As--fitted position secured against rotation

Rotate as--fitted position
"
Undo the bolt on the handle and remove the handle.
"
Lift up the guide washer and refit it rotated through 90_.
WK06_009_9909
Maintenance Card
06--009
Page 5 of 10
20202303
KEP valve closed
WK06_009_9909
"
Replace the handles and close the ball valve.
"
Press the Stroke change--over button when the concrete pump

is running and hold it down until the concrete pump switches off.
"
You must switch the concrete pump off when the drive cylinders
have reached the end position. Then you can release the Stroke
change--over button.
649
Maintenance Card
06--009
Page 6 of 10
Piston replacement
When replacing pistons you may work with the remote control on the
platform.
5
10600301
1
2
3
4
5
650
Piston rod flange

Fastening bolts
Securing wire
Delivery piston
Spacer flange
"
Shut the machine down.
"
Drain the water from the water box and remove the cover.
"
Start the machine up.
"
Move the drive piston of the delivery piston to be removed to its

end position. The spacer flange must be fully visible in the water
box.
"
"
Remove the securing wire from the fastening bolts.
WK06_009_9909
Maintenance Card
06--009
Page 7 of 10
10600701
Fastening bolts
"
Unscrew the fastening bolts for the spacer flange from the drive
piston rod and from the delivery piston and remove the spacer
flange.
"
"
Slowly bring the drive piston rod up to the delivery piston.
"
1
10600800
WK06_009_9909
Pulling bolts
651
Maintenance Card
06--009
Page 8 of 10
"
Remove the protective caps from the two pulling bolts and bolt
the delivery piston to the drive piston using the two pulling bolts.
"
"
Pull the delivery piston completely out of the delivery cylinder.
"
"
Undo the threaded joint 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.
652
"
Grease a new delivery piston heavily with acid--free grease (e.g.,

Vaseline).
"
Bolt the new delivery piston to the drive cylinder using the two
pulling bolts.
"
"
Slowly advance the drive piston rod and push the new delivery
piston carefully into the delivery cylinder. The pulling bolts must
remain freely accessible.
"
WK06_009_9909
Maintenance Card
06--009
Page 9 of 10
"
Unscrew the pulling bolts and replace the protective caps.
"
"
Retract the drive piston rod sufficiently for the spacer flange to
fit between the delivery piston and the drive piston.
"
"
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.
20202301
Open the KEP valve and secure it against rotation
WK06_009_9909
"
Open the KEP valve when delivery piston replacement is completed.
"
Replace the guide washer so that it is blocked in position, fit the

handle and bolt it down.
"
Then carry out a test run.
653
Maintenance Card
06--009
Page 10 of 10
654
WK06_009_9909
Maintenance Card
07--001
Page 1 of 2
6.13
Lubricating the
S Transfer Tube
This maintenance card describes the lubrication of all lubrication points

on the transfer tube if you do not have a centralized lubrication system.
You will find the maintenance intervals in the maintenance summary at
the start of this chapter.

Grease gun
Note
Refer to the Recommended Lubricants section on page 610 for an
appropriate grease to use.
Lubrication intervals
You should grease the lubrication points hourly, unless a different

interval is specified. At the end of the day to purge grout, you should
apply the grease until you can see it escaping.
30300103
Transfer tube and plunger cylinder lubrication diagram
WK07_001_9909
655
Maintenance Card
07--001
Page 2 of 2
656
WK07_001_9909
Maintenance card
07--011
Page 1 of 24
6.14
S Transfer Tube
This maintenance card describes how to replace the S transfer tube and its
wear parts. You will find the maintenance intervals in the maintenance
Measuring the wall thickness
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).
Torques
The tightening torques are listed in the General tightening torques

section at the start of the Maintenance chapter. Torques differing
from these are specified in the spare parts sheets.
Danger
Shut down the machine before commencing work and secure it against
unauthorized or accidental starting. Dump the accumulator pressure.
Use only suitable lifting equipment for lifting components.
Note
The wear parts must be replaced if visual inspection reveals wear or if there
is insufficient pressure build-- up in the delivery line.
WK07_011_0407
6 57
Maintenance card
07--011
Page 2 of 24
S transfer tube
variants
wk07_011_0407en1
No. 0
1
2
Designation
S transfer tube with bolted switching shaft
S transfer tube with welded switching shaft
Note
Whatever variant of S transfer tube fitted, the recommended procedure 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.
6 58
wk07_011_0407en
Maintenance card
07--011
Page 3 of 24
Overview
3
10
8
30300101
No. 0
1
2
3
4
5
6
7
8
9
10
11
wk07_011_0407en
Designation
Plunger cylinder
Retaining plate
Retaining plate fastening bolts
Clamping bolts with nuts
Switch lever
Hexagon nut on the switching shaft
Fastening bolt for flanged bearing (10)
B fastening bolts for spectacle wear plate
A fastening bolts for spectacle wear plate
Flanged bearing
(not shown) Two jacking bolts
6 59
Maintenance card
07--011
Page 4 of 24
Removing the transfer

tube bearing
The S transfer tube is mounted in the transfer tube bearing in the

rear wall of the hopper.
"
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.
No. 0
1
2
3
4
6 60
4
10800901
Designation
Fastening bolts
Jacking bores with jacking thread
Transfer tube bearing
Hinged elbow
"
Swing the hinged elbow (4) to one side.
"
Remove the two fastening bolts (1) for the transfer tube bearing (3)
and force the bearing out by screwing the two jacking bolts supplied
into the jacking bores.
"
Check the seal rings and O--rings in the transfer tube bearing for wear
and replace as required.
wk07_011_0407en
Maintenance card
07--011
Page 5 of 24

seal set
10801000
Bend the seal rings to make installation easier
Caution
The mounting position for the seal set in the transfer tube bearing can be
found in the accompanying spare parts sheet.
"
Grease the new seal set and fit it as illustrated 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 lubricant through the apertures.
wk07_011_0407en
6 61
Maintenance card
07--011
Page 6 of 24
Removing the switching shaft bearing

(flanged bearing)
The switching shaft of the S transfer tube is mounted in the switching

shaft bearing (flanged bearing) in the front wall of the hopper.
"
Remove any lubrication lines on the retaining plate and flanged bearing.
10300700
Unbolting the retaining plate
"
Undo the fastening bolts on the retaining plate and remove the retaining plate. (You will have to replace the locking plates on the fastening
bolts with new ones on reassembly.)
Collect the escaping hydraulic fluid in a suitable container and dispose of it
in accordance with the disposal regulations applicable for your region.
"
6 62
If necessary for space reasons, disconnect the hydraulic hoses leading

to the plunger cylinders at the bulkhead unions. Then close off the hydraulic lines with plugs.
wk07_011_0407en
Maintenance card
07--011
Page 7 of 24
10300800
Removing the plunger cylinders
Note
The plunger cylinders can be pushed back as illustrated. It is, however, 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.
"
Push back the pistons in the plunger cylinders and remove the plunger
cylinders with the hydraulic hoses.
"
Undo the hexagon nut on the switching shaft and remove the spacer
ring.
10700200
Loosening the clamping bolts
"
wk07_011_0407en
Undo the clamping bolts on the switch lever.
6 63
Maintenance card
07--011
Page 8 of 24
"
Spread the switch lever apart by screwing the two jacking bolts supplied into the two bores.
"
Withdraw the switch lever from the switching shaft.
1
2
3
10700300
No. 0
1
2
3
6 64
Designation
Fastening bolt
Jacking bores (2 diagonally opposed)
Flanged bearing
"
Unscrew the fastening bolt (1) from the flanged bearing (3).
"
Force the flanged bearing off by screwing the two jacking bolts supplied into the jacking bores (2).
"
Check the seal rings and O--rings in the flanged bearing for wear and
replace these as required.
wk07_011_0407en
Maintenance card
07--011
Page 9 of 24
Flanged bearing
seal set
10700400
Removing the retaining ring
"
Remove the retaining ring.
10700500
Removing the old seal set
"
wk07_011_0407en
Remove the old seal set. It may be necessary to cut the seal rings to do
this.
6 65
Maintenance card
07--011
Page 10 of 24
10700600
Fitting the new seal set
Caution
The mounting position for the seal set in the flanged bearing can be found in
the accompanying spare parts sheet.
"
Grease the new seal set and fit it as illustrated on the spare parts sheet.
Note
Clean the flanged bearing before refitting and grease the seals. Check the
sleeve for wear and replace if necessary.
6 66
wk07_011_0407en
Maintenance card
07--011
Page 11 of 24
Removing the spectacle wear plate
10700800
Pushing the S transfer tube to one side
"
Push the S transfer tube away from the spectacle wear plate.
1
30300102
No. 0
1
2
"
wk07_011_0407en
Designation
B fastening bolts
A fastening bolts
Undo the 8 fastening bolts and remove the spectacle wear plate from
the transition liner.
6 67
Maintenance card
07--011
Page 12 of 24
Removing the S transfer tube
Replace the S transfer tube if the wall thickness has fallen below the
minimum.
Maintenance card: Measuring the wall thickness
Note
If there is no need to replace the S transfer tube or the wear sleeve in the S
transfer tube outlet, you may skip this operation and continue at the Fitting
the spectacle wear plate operation.
10801200
Removing the agitator shaft
"
6 68
Remove the agitator shaft.
wk07_011_0407en
Maintenance card
07--011
Page 13 of 24
10700900
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 you wish only to replace the wear sleeve, you must also carry out the
operations on the next page and only then fit the S transfer tube again.
If you are replacing the complete S transfer tube, fit the new tube in the
reverse sequence to disassembly.
"
wk07_011_0407en
Fit the new S transfer tube.
6 69
Maintenance card
07--011
Page 14 of 24
Replacing the
wear sleeve in the
S transfer tube
The wear sleeve can be replaced without the requirement to replace

the S transfer tube if the wear sleeve is heavily worn. The S transfer
tube must be removed to do this.
Danger
There is a risk of burning during heating and fitting of the new wear sleeve.
Use suitable protective equipment.
Caution
Do not damage the transfer tube when cutting off the wear sleeve.
10701001
Wear sleeve
"
Carefully cut the wear sleeve at two opposing points using an angle
grinder and remove the two parts.
Note
The wear sleeve is chrome--plated and therefore must not be heated locally
or to too great a temperature.
6 70
"
Heat the new wear sleeve uniformly to a maximum temperature

of 140 _C.
"
Place the heated wear sleeve over the transfer tube outlet and allow
the wear sleeve to cool.
"
Replace the S transfer tube.
wk07_011_0407en
Maintenance card
07--011
Page 15 of 24
Fitting the spectacle

wear plate
Screw two short threaded rods into the two upper threaded bores in
the spectacle wear plate and insert these into the upper holes in the
hopper wall to make positioning of the spectacle wear plate easier
during fitting.
"
Check the O--rings in the intermediate rings on which the spectacle

wear plate is placed.
"
Clean the mounting surfaces and grease them with a multipurpose

grease.
Caution
The spectacle wear plate rests only against the O--rings of the intermediate
rings. There is a small clearance between the spectacle wear plate and the
hopper wall. The B fastening bolts (outer fastening bolts) should therefore
initially only be tightened finger--tight, as otherwise the spectacle wear plate
may be broken.
10801300
Fitting the spectacle wear plate
"
wk07_011_0407en
Fit the new spectacle wear plate.
6 71
Maintenance card
07--011
Page 16 of 24
1
max. 0.5 mm
2
30800101
No. 0
1
2
6 72
Designation
Spectacle wear plate
Intermediate ring
"
Put the new spectacle wear plate in place and fasten it with the B fastening bolts (outer fastening bolts). Tighten these only to finger--tightness initially.
"
Bolt down the spectacle wear plate with the A fastening bolts (top and
bottom) and tighten them to the appropriate tightening torque.
"
Tighten the B fastening bolts to the tightening torques given in the

accompanying spare parts sheet. The spectacle wear plate may only be
distorted by a maximum of 0.5 mm when the bolts are tightened.
wk07_011_0407en
Maintenance card
07--011
Page 17 of 24
Replacing the
wear ring
Replace the wear ring in the event of heavy visible wear, if concrete
is leaking or if there is inadequate pressure build--up in the delivery
line.
2
1
10701002
No. 0
1
2
wk07_011_0407en
Designation
Thrust ring
Wear ring
"
Remove the old wear ring and the thrust ring.
"
Fit a new thrust ring and a new wear ring in the S transfer tube.
6 73
Maintenance card
07--011
Page 18 of 24
Fitting the transfer

tube bearing
10800900
Note
Pay attention to the location of the lubrication openings when fitting the
transfer tube bearing.
"
6 74
Fit the transfer tube bearing on the S transfer tube outlet and bolt it
securely.
wk07_011_0407en
Maintenance card
07--011
Page 19 of 24
Wear sleeve and collared washer
10701100
Locating the collared washer
"
Bend the tab on the collared washer downwards.
"
Place the collared washer on the flanged bearing housing so that the
tab is located in the bore, thereby securing the washer against rotation.
"
Insert the wear sleeve into the flanged bearing housing.
Note
Note the location of the lubrication bores when fitting the flanged bearing.
wk07_011_0407en
"
Grease the inside of the wear sleeve with Anti--Seize AS 450 Assembly Paste or an equivalent assembly grease.
"
Locate the complete flanged bearing on the switching shaft and bolt it
tight.
"
Locate the wear sleeve on the switch lever.
6 75
Maintenance card
07--011
Page 20 of 24
Mounting the
switch lever
wk07_011_0407en2
Aligning the switch lever
Note
The topmost tooth of the switching shaft is slightly flattened and may be used
as a marker.
6 76
"
Grease the teeth on the switch lever and the switching shaft with
Anti--Seize AS 450 Assembly Paste or an equivalent assembly
grease.
"
Fit the switching lever in such a way that the flattened tooth on the
switching shaft is located in the notch in the switching lever and the
wear sleeve is form--fitted on the switching lever.
wk07_011_0407en
Maintenance card
07--011
Page 21 of 24
30300101
No. 0
1
2
3
"
Designation
Spacer ring
Switching shaft
Hexagon nut
Fit the spacer ring (1) on the switching shaft (2) and screw the hexagon nut (3) onto the switching shaft.
Note
The gap (clearance between wear ring and transfer tube) must be set to
ensure that the transfer tube switches correctly.
wk07_011_0407en
6 77
Maintenance card
07--011
Page 22 of 24
No. 0
1
2
3
4
5
6
7
6 78
wk07_011_0407en3
Designation
Spectacle wear plate
Wear ring
Transfer tube
Thrust ring
Hexagon nut
Gap between wear ring and transfer tube
Wear ring is flat against the spectacle wear plate
"
First tighten the hexagon nut (5) on the switching shaft so that the
wear ring (2) lies flat (7) against the spectacle wear plate (1).
"
Then slowly tighten the hexagon nut (5) further until the transfer
tube (3) lies against the wear ring (2).
This will prestress the thrust ring (4).
"
Then undo the hexagon nut (5) on the switching shaft by about of a
turn. This will automatically set the gap required (6) between the
transfer tube (3) and the wear ring (2).
A small gap is created between the wear ring and the transfer tube.
The wear ring is pressed against the spectacle wear plate by the
lightly prestressed thrust ring.
wk07_011_0407en
Maintenance card
07--011
Page 23 of 24
Note
Use only new nuts for the clamping bolts.
"
Insert the two clamping bolts in the switch lever and fit new nuts.
Tighten the clamping bolts in accordance with the General tightening
torques table.
"
Further assembly is carried out in the reverse sequence to disassembly.
Note
The hydraulic lines must be bled after reassembly. Do this by starting up the
pump slowly and switching the transfer tube across slowly a few times.
wk07_011_0407en
6 79
Maintenance card
07--011
Page 24 of 24
6 80
wk07_011_0407en
Maintenance Card
10--007
Page 1 of 6
6.15
Measuring the
Wall Thickness
(Machines with
S Transfer Tube)
This maintenance card describes how to measure the wall thickness of

delivery lines. You will find the service intervals in the maintenance
summary at the start of this section.

Wall thickness measuring device
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 if it reaches the right delivery pressure, particularly if a blockage has built up, if the wall thickness of the delivery
line has declined below the minimum required.
Caution
Only tap the delivery line with hardwood (hammer handle). Otherwise
dents may be caused which lead to even faster 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.
WK10_007_9909
681
Maintenance Card
10--007
Page 2 of 6
11000101
Tapping the delivery line with a hammer handle
Straight pipes
Uniform wear can be achieved by regularly rotating the straight

delivery pipes 120.
The minimum wall thickness for straight pipes is shown in the
following graph.
Elbows
Uniform wear can be achieved by regularly rotating the elbows 180.

The wear on the external radius of an elbow 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 an
elbow.
The minimum wall thickness for elbows is shown in the following
graph.
11000200
Rotate delivery pipes and elbows regularly
682
WK10_007_9909
Maintenance Card
10--007
Page 3 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
transfer tube is subject to greater stress at the point at which the torque
is applied (switching shaft -- transfer tube connection) must be taken
into consideration.
12501601
Area of significant loading
Maximum possible operating pressure
Guide value for wall thickness
up to 130 bar
approx. 3 mm
over 130 bar
approx. 5 mm
Note
We must emphasis the fact that the transfer tube is subject to variable
degrees of loading as a consequence of the dynamic loading during
pumping. There is no general method for calculating this loading,
which depends on the individual circumstances, and so the delivery line
can also burst at an operating 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.
WK10_007_9909
683
Maintenance Card
10--007
Page 4 of 6
Measuring
Follow the operating instructions supplied with the measuring device

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 following graph.
Caution
Pipes and elbows 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 falls below the
minimum.
Note
As a rule it is possible to continue pumping with a lower operating
pressure 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 this
loading, which depends on the individual circumstances, and so the
delivery line can also burst at an operating 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
adequate and the delivery line will burst.
684
WK10_007_9909
Maintenance Card
10--007
Page 5 of 6
Graph
Minimum wall thickness as a function of operating pressure
[bar] 250
240
230
220
210
200
190
180
170
160
150
140
130
120
110
100
90
2
80
70
60
50
40
30
20
10
0
0.0 0.5 1.0
1.5 2.0
2.5 3.0
1
2
WK10_007_9909
3.5 4.0
4.5 5.0
5.5 6.0
6.5 7.0
7.5 8.0
8.5 9.0
9.5 10.0
[mm]
High pressure
Maximum delivery pressure
685
Maintenance Card
10--007
Page 6 of 6
686
WK10_007_9909
Maintenance Card
20--044
Page 1 of 2
6.16
Lubricating the
M 36Z Placing Boom

on the placing boom if you do not have a centralized lubrication
system. You will find the maintenance intervals in the maintenance

Grease gun
Note
Refer to the Recommended Lubricants section on page NO TAG for
an appropriate grease to use.
Lubrication intervals
You should grease the lubrication points every week, unless a different
interval is specified. You should apply the grease until you can see it
escaping.
WK20_044_0102 4
M 36Z placing boom lubrication diagram
WK20_044_0102
687
Maintenance Card
20--044
Page 2 of 2
688
WK20_044_0102
Maintenance Card
21--011
Page 1 of 2
6.17
Lubricating the
Boom Pedestal
(TRDI 70)

on the boom pedestal if you do not have a centralized lubrication
system. You will find the maintenance intervals in the maintenance

Grease gun
Note
Lubrication Intervals
WK21_011_9909
You should grease the lubrication points daily, unless a different

interval is specified. You should apply the grease until you can see it
escaping.
689
Maintenance Card
21--011
Page 2 of 2
Lubrication Points with No Central Lubrication Manifold
Lubrication Diagram for TRDI 70 Boom Pedestal
Lubrication Points with Central Lubrication Manifold
Lubrication Diagram for TRDI 70 Boom Pedestal
690
WK21_011_9909
Maintenance Card
25--001
Page 1 of 8
6.18
Replacing the
Delivery Line
This maintenance card describes how to replace the delivery line and
its seals. You will find the maintenance intervals in the maintenance
Measuring the wall thickness

4 mm feeler gauge
General
The delivery line is subdivided into two sections:

-- Boom delivery line
-- Pump--boom delivery line.
These comprise:
-- bends;
-- straight pipes of uniform length;
-- adapter pipes (straight pipes manufactured individually for each arm
package in order to fit the delivery line to the arm lengths).
Wall thickness
Measure the wall thickness of the delivery line to determine which pipe
sections need to be replaced.
Maintenance card: Measuring the wall thickness
The starting points for laying the pipe on the boom are the hinge pivot
points. The straight sections of the delivery line run from pivot point to
pivot point. The delivery line is matched to the arm length concerned
by means of the adapter pipes. The length of the pump--boom delivery
line is also adapted by means of adapter pipes.
WK25_001_9909
691
Maintenance Card
25--001
Page 2 of 8
Adapter pipe length

plate
2
3
4
7
8
1
2
3
4
5
6
7
8
Ordering
First adapter pipe on A arm (L1)

Second adapter pipe on A arm (L1.1)
First adapter pipe on B arm (L2)
Second adapter pipe on B arm (L2.1), etc.
First pipe in pump -- boom delivery line (V1)
Second pipe in pump -- boom delivery line (V2), etc.
V8 and V9 are adapter pipes for lateral outlets
V10 is always the riser pipe
The length of the adapter pipes differs according to the machine and
boom. For re--ordering purposes, you should take the lengths and
location of all the adapter pipes on your machine from the adapter
pipes plate next to the rating plate or from the following spare parts
sheets:
-- Boom delivery line:
Spare parts sheet group 25.0
-- Pump--boom delivery line:
Spare parts sheet group 25.3
The adapter pipe lengths plate is located on the boom
692
WK25_001_9909
Maintenance Card
25--001
Page 3 of 8
When ordering adapter pipes you should always state:

-- Machine number
Example: 22/.....
-- Mounting position
L3.1
-- Length in mm
1377 mm
-- Diameter DN
DN 125
Caution
You must not exceed the delivery line wall thickness specified on
the rating plate and in the machine card. The additional weight can
impair the machines stability.
Note
Should you wish to re--equip your machine to a delivery line of greater
wall thickness, the machines stability will have to be recalculated and
checked and approved by an authorized inspector.
Untensioned
assembly
The boom delivery line must be fitted with the arm assembly fully
relieved of tension:
-- the arm assembly is not under tension in the transport position if
each arm is lying freely on the rest provided for this purpose;
-- the arm assembly is not under tension when unfolded if each arm is
supported.
Caution
If the tension on the arm package is not fully relieved during assembly,
stresses may occur in the delivery line on movement of the placing
boom and consequential damage may be caused to the pipe brackets
and to the placing boom. Furthermore, the boom may swing up and
down causing the end hose to swing and strike out during pumping
operations.
WK25_001_9909
693
Maintenance Card
25--001
Page 4 of 8
Clearance
A clearance of 4 mm must be maintained between the delivery pipes

over the whole of the delivery line, so that the welding neck rings can
butt against the couplings without play. This clearance is achieved
either:
-- automatically, through the use of a C seal (triple--lip seal), or
-- manually, by adjustment, using a feeler gauge.
Seal
C seals (triple--lip seals) are used where the delivery line runs in a
straight line and there is no rotational movement. The 4 mm clearance
is created automatically.
Caution
No triple--lip seals (C seals) may be used in the pivot joints in the pipe
bends.
A seals are used:

-- if the delivery line does not run in a straight line;
-- in the pivot joints; and
-- at the assembly coupling at the tip of the boom.
The spacing of 4 mm must be set using the feeler gauge.
Coupling
Couplings with lever closures must be secured with a spring clip.
11000800
Securing couplings with lever closures
Couplings with a threaded closure are closed using self--locking nuts.

These nuts may not be re--used, but must be replaced each time the
coupling is fitted.
694
WK25_001_9909
Maintenance Card
25--001
Page 5 of 8
Fitting an A seal
4 mm
Set the spacing with the feeler gauge
WK25_001_9909
"
Push the A seal over the fixed delivery line pipe.
"
Lay the pipe to be attached in the pipe bracket and push it up to

the fixed pipe.
"
Set the clearance of 4 mm between the pipes using a feeler

gauge.
"
Fix the pipe to be attached in the pipe brackets.
"
Push the A seal over the two weld--on rings.
"
Fit the coupling and secure it.
695
Maintenance Card
25--001
Page 6 of 8
Caution
No triple--lip seals (C seals) may be used in the pivot joints.
Fitting a C seal
4 mm
The spacing is created automatically by the ring seal
696
"
Push the C seal over the welded--on ring of the fixed delivery
line pipe.
"
Lay the pipe to be attached in the pipe bracket and push it up to

the fixed pipe.
"
Push the pipe to be attached as far as the stop in the ring seal.
"
Fix the pipe to be attached in the pipe brackets.
"
Fit the coupling and secure it.
WK25_001_9909
Maintenance Card
25--001
Page 7 of 8
Boom delivery line
The starting points for laying the pipe on the boom are the pivot points.
"
Grease all couplings and seals well internally before assembly.
Note
WK25_001_9909
"
Install the bends in the fitting couplings at the pivot points.
"
Align the bends such that the straight pipes can be connected
without tension.
"
Fix the bends.
"
Install the fixed length delivery pipes.
"
Install the adapter pipes last.
697
Maintenance Card
25--001
Page 8 of 8
Pump- boom
delivery line
The pressure pipe is the starting point for assembly.

Note
You should use only high--pressure pipes when replacing these delivery
line pipes.
Only C seals (triple--lip seals) are used throughout the pump--boom
delivery line.
"
Grease all couplings and seals well internally before assembly.
Note
698
"
Fit the reducer pipe to the pressure pipe with a clamp coupling.
The clamp coupling must be capable of rotating with the pressure pipe. The reducer pipe, which must be located in a vibration
absorber, may not turn either.
"
Fit the boom connection pipes as far as the bend on the riser
pipe.
WK25_001_9909
Troubleshooting Guide
The previous sections of this manual dealt with the various aspects of
operation, preventative maintenance, adjustments, and component
replacement. This troubleshooting section will assist you in
recognizing and recovering from conditions that cause equipment
malfunctions.
This topic:
A820062_07_0208D
Starts on page:
7.1 Concrete Pump
72
7.2 Placing Boom
78
7.3 Boom Control
79
7.4 Electrical System
79
71
7.1
Concrete Pump
This section describes the possible causes of defects which may affect
the concrete pump and how to rectify them. The numbers in
parentheses are the item numbers on the hydraulic schematic.
The delivery pistons do not start

Cause
Remedy
Pump not switched on
With truck transmission in neutral and parking brake on, start truck
engine and engage concrete pump PTO. Verify that green PTO light
illuminates and place in correct pumping gear.
Lack of fluid in the hydraulic

system
Top up hydraulic fluid.
No accumulator pressure
(
(see
test reading
di ffor required
i d
value)
On older machines, close accumulator dump valve (121).
120
119
119
On newer machines, verify that hopper grate is closed and then manually
push solenoid-operated accumulator dump valve (184) to see if
accumulator pressurizes. If accumulator pressurizes (when dump valve
is pressed), problem is in the dump valve or its circuitry.
181
119
Vacuum meter (136) in the

red zone
72
184
120
Vacuum filter (140) dirty. Replace filter element (141), clean

magnetic rod, observe maintenance intervals.
A820062_07_0208D
The delivery pistons do not start

Cause
Remedy
Hydraulic fluid too cold
Allow hydraulic fluid to warm up by idling.
Main hydraulic system pump

(127) not engaged for
operation
Increase delivery rate regulation by:

(1) Using electric volume control switch (211), or
Delivery piston blocked in

the
h end
d position
ii
Press reverse pumping switch or stroke change switch.
(2) Closing manual volume control valve (125)
10600100
Engine speed too low. The

main pump does not engage.
Increase engine speed.
Pump has insufficient output

Cause
Remedy
Main hydraulic system pump

(127) not fully engaged
Increase delivery rate regulation by:

(1) Using electric volume control switch (211), or
(2) Closing manual volume control valve (125)
A820062_07_0208D
73
Pump is not running

Cause
Remedy
Lack of fluid, machine

switches off automatically
Stroke change valve (103a)

sticks as a result of fine dirt
or defect
Press stroke change valve manual operation button (103a) a number of

times, switch the pump over to reverse pumping for 2 -- 3 strokes. Check
solenoid coils and their connections.
120
119
184
103a
106
121
196
211
108
142
74
181
125
183
A820062_07_0208D
Pump does not switch over

Cause
Remedy
Too little hydraulic fluid
Fuse blown
Replace fuse.
Stepping relay in the switch

cabinet defective
Operate stroke change function. Verify that LED on the stroke change
module illuminates during cycle. If LED does not illuminate, check
stepping relay.
Stroke change valve (103a)

sticks as a result of fine dirt
or defect
Press stroke change valve manual operation button (103a) a number of

times, switch the pump over to reverse pumping for 2 -- 3 strokes. Check
solenoid coils and their connections.
120
119
184
103a
106
121
196
211
108
142
A820062_07_0208D
181
125
183
75
Transfer tube does not switch or gets stuck

Cause
Remedy
Insufficient accumulator
pressure, accumulator
l
circuit
i i
not pressurized (see test
reading for required value),
change-over pressure is too
low, or accumulator dump
valve (184) is open.
On older machines, close accumulator dump valve (121).
120
119
119
On newer machines, verify that hopper grate is closed and then manually
push solenoid-operated accumulator dump valve (184) to see if
accumulator pressurizes. If accumulator pressurizes (when dump valve
is pressed), problem is in the dump valve or its circuitry.
181
119
Accumulations of aggregate
in the range through which
the transfer tube swings,
deposits in the hopper
184
120
Remove by repeated change-over and reverse pumping, if necessary,

open hopper and clean. Request concrete complying with the standard.
Set transfer tube hard/soft shift valve (181) to hard shift position (i.e.,
open).
Accumulator empties too quickly or no pressure

Cause
Remedy
Hopper grate is open or

solenoid-operated dump
valve (184) is not operating
properly
Verify that hopper grate is closed and then manually push

solenoid-operated accumulator dump valve (184) to see if accumulator
pressurizes. If accumulator pressurizes (when dump valve is pressed),
problem is in the dump valve or its circuitry.
76
A820062_07_0208D
Hydraulic fluid is getting too hot

Cause
Remedy
Too little cooling water in

the
h water box
b at hi
highh output
Top up the water.
10600200
Cooling water too hot
Replace with fresh water.
Too little fluid in the

hydraulic system
Pump is running in the

maximum pressure range
because of poor concrete and
high delivery rate
Reduce pump delivery speed or ask for better concrete (composition).
Constantly at maximum
pressure in long--distance
delivery
Increase pipe size, eg from 4 (DN 100) to 5 (DN 125).
Overpressure as a result of a
blockage
Remove blockage (by switching the pump over from delivery to reverse
pumping a number of times).
10600100
Radiator (132) dirty, radiator

fan not running
A820062_07_0208D
Switch on.
Clean.
Check voltage and ground contact of thermocouple 131F(55C)
(not on front--mounted radiator).
77
7.2
Placing Boom
This section describes the possible causes of defects which may affect
the boom and how to rectify them.
Danger
Only carry out maintenance and repair work on the placing boom if the
placing boom is retracted or properly supported, the engine is switched
off and the support legs are secured.
12000401
Supporting the boom
The boom can be slewed in a full circle without limitation (machines with slewing gear
transmission)
Cause
Remedy
The slewing gear limit

switch is defective or the
limit switch actuator is bent
Repair slewing gear limit switch.
Caution
The hydraulic and electric lines can be damaged if the
mast is slewed in the same direction a
number of times.
78
A820062_07_0208D
7.3
Boom Control
This section describes the possible causes of defects affecting the

proportional boom control and how to remedy them.
Boom control has failed completely, no boom arm or support foot can be shifted
Cause
Remedy
EMERGENCY OFF
function has been activated
Unlock all EMERGENCY SHUT--DOWN push-buttons. If necessary,

change from the radio control system to the cable control.
The mode select operating

valve does not become live
when the boom control is
switched on
Check fuses. Operate EMERGENCY SHUT--DOWN valve by hand. If

necessary, replace EMERGENCY SHUT--DOWN valve.
7.4
Electrical System
Emergency measure:
Execute individual boom functions by the manual lever with the
EMERGENCY SHUT--DOWN valve pressed in.
This section describes the possible causes of faults in the electrical
system and how to rectify them.
The radio transmitter has to be shaken to activate it

Cause
Remedy
The batteries have

inadequate contacts in the
battery compartment
Clean the contacts in the battery compartment thoroughly and bend

carefully.
Pump is switched on, but will not start

Cause
Remedy
The specified minimum

engine speed for pumping
operations
i
off 900 rpm iis not
achieved
Increase engine speed.
A820062_07_0208D
79
Pump is switched on, but will not start

Cause
Remedy
Pumping rate too low
Increase pumping rate.
EMERGENCY
SHUT -DOWN
SHUTDOWN is
i activated
i
d
(EMERGENCY
SHUT--DOWN button
pressed)
Unlock all EMERGENCY SHUT--DOWN buttons.
10500200
The red indicator light for fluid overheating is lit

Cause
Remedy
The hydraulic fluid has

overheated
Allow the hydraulic fluid to cool and, if necessary, top up or

replace the water in the water box.
The fan on the heat

exchanger is defective
Check fan function and replace the fan motor if necessary.
Temperature sensor B1 is
defective
Replace temperature sensor. Hold temperature sensor connection to

ground to check.
The connection cable to the

temperature sensor is loose
Clean and fasten the connections on the temperature sensor.
710
A820062_07_0208D
The red indicator light for fluid overheating is lit

Cause
Remedy
The fan connection is

corroded
Clean the terminals on the fan motor and fasten the connection cables
properly.
Caution
Avoid contact with ground.
The vibrator fuse is blown

Cause
Remedy
The vibrator is defective or

the hopper grate is loose
Replace defective vibrator. Fasten the grate cover on the hopper and
reduce the out--of--balance of the vibrator, if necessary.
Vibrator cable is damaged
Replace vibrator cable.
A820062_07_0208D
711
The fan on the oil cooler no longer switches in automatically

Cause
Remedy
Thermal contact switch B2

defective (seat on the
connecting flange of the
cooler)
Check terminal (and ground contact). Replace thermal contact switch (do
not forget copper gasket). Switch on cooler motor by the manual switch.
10501100
The radio remote control no longer operates perfectly, some functions are incorrect
Cause
Remedy
Fuses in the receiver or

transmitter have blown
Check fuses.
To replace transmitter fuse, open transmitter casing with 4 mm allen key.
To check the fuse in the receiver, unscrew casing lid, undo the front
printed circuit board (PCB) and flap down. The microfuses are mounted
on the rear PCB. The current ratings are marked next to the fuses.
The engine speed reduces spontaneously

Cause
Remedy
EMERGENCY
SHUT--DOWN pulses from
the radio control system
Brief EMERGENCY SHUT--DOWN pulses from the radio control

system can be caused by radio interference. If necessary, move the
transmitter site. In some circumstances on particular construction sites it
will be necessary to work with the cable remote control system. Change
channel if the radio control system has channel selection.
712
A820062_07_0208D
The pump no longer switches over on every other stroke

Cause
Remedy
Defective proximity switch,

cable, or junction box.
Refer to Proximity Switch Junction Box section on page 336 and

Proximity Switch Connector section on page 338. Replace defective
component(s).
Note
On older models (with proximity switches in the water
box), a red LED on the side of the proximity switches
lights up when they are approached with a metallic object (but not touched).
One coil on the stroke

change
h
valve
l (103a)
(103 ) is
i
defective
Replace stroke change valve (103a).
120
119
184
103a
106
A820062_07_0208D
121
196
211
108
142
Connecting plug on the

stroke change valve (103a)
corroded
181
125
183
Check connector on the stroke change valve (103a).
713
714
A820062_07_0208D
Index
A
accumulator, 347
- maintenance, 627
- troubleshooting, 76
centralized lubrication system

- grease, 68
- indicator lamps, 324
- low temperature grease, 68
- technical data, 323
accumulator dump cock, 347
charging and gauging kit, 625
accumulator dump valve, 347
cleaning
- catch basket, 552
- cement bags, 554
- compressed air cleaning, 552
- concrete pump, 550
- delivery cylinder, 561
- delivery line, 556
- high--pressure water cleaning, 554
- hopper, 561
- leavings, 551, 561
- mark the water hose, 555
- methods of cleaning delivery lines, 557
- post--washing operations, 564
- preparations for cleaning, 550
- S--tube, 561
- sponge ball, 551
- suction cleaning, 558
- truck superstructure, 564
- wash--out adapter, 553
agitator hopper, pumping operations, 541

agitator lever, 345
agitator safety cut--out, agitator shut--off valve, 341
agitator shut--off valve, 341
Antennae, Radio, telephone etc., 331
B
bad weather, 528
blockages, 546
boom
- bounce, 542
- description of the functions, 36
- favorable boom position, 542
- impermissible working range, 539
- rating plate, 34
- unfolding, 534
boom control, troubleshooting, 79
clearances
- high voltage lines, 530
- minimum clearance from pits, 59
- safe clearances from pits, 510
boom control unit, inspection, 56
cold weather, 528
boom movements, 527

- danger zone, 529
- hand signals, 533
- high voltage lines, 530
- horn, 531
- prohibited activities, 527
- uncontrolled boom movements, 532
- uncontrolled sinking as a result of hydraulic fluid cooling,
531
components, summary, 32
bouncing boom, 542

breaks in pumping, 545
C
cable remote control, 326
- setup, 520
catch basket, 552
central module control cabinet, multiple display, 318
Index
compressed air cleaning, 552

concrete brake, 352
concrete pump, description of the functions, 37
control block
- boom, 344
- outriggers, 343
control cabinet, central module control cabinet, 316
control devices
- agitator lever, 345
- boom control block, 344
- cable remote control, 326
- central module control cabinet, 316
- control panel in the steps, 321
- hydraulic fluid radiator, 355
- output controller, emergency operation, 349
- outriggers control block, 343
- proximity switch junction box, 336
- radio remote control, 328
A1
Index
- vibrator, 354
- water pump lever, 346
control panel, in the steps, 321
filter functions
- boom filter, 54
- vacuum filter, 54
coolant overheating, 319
flared screwed joint, 66
corner bearing load, 514
flow restrictor on the end hose, 352

flushing water pump, 350
D
danger zone
- boom movements, 529
- pumping operations, 540
- setup site, 512
delivery cylinder, cleaning, 561
delivery line
- cleaning, 556
- measuring the wall thickness (machines with S transfer
tube), 681
- replacing, 691
delivery piston
- piston replacement with KEP, 645
driving, 42
- during the journey, 43
E
EMERGENCY SHUT--DOWN button, 331, 334, 56
EMERGENCY SHUT--DOWN function, 55
emergency stroke kit, 572
End hose
- Extending, 2 6
- With spout, 2 6
function checks, 53, 623

- boom control unit inspection, 56
- EMERGENCY SHUT--DOWN function, 55
- filter functions, 54
- proximity switch, 53
- pump functions, 53
function description, 36
- boom, 36
- concrete pump, 37
- delivery line, 36
- hydraulic control, 36
- outriggers, 36
- transfer tube, 37
functional fluids, 67
fuse, troubleshooting, 711
H
hand signals
- boom movements, 533
- pumping operations, 533
high voltage lines, 530
high--pressure water cleaning, 554
highway travel, 42
hopper, cleaning, 561
hopper grate safety switch, 339
hoses, maintenance, 639
end hose, 351, 540

- concrete brake, 352
- danger zone, 540
- retaining rope, 353
- with flow restrictor, 352
hydraulic control, description of the functions, 36
engine, troubleshooting, 712
hydraulic fluid radiator, 355
hydraulic fluid, 67
- full fluid change, 617
- radiator, 355
- troubleshooting, 77, 710
hydraulic system
- accumulator maintenance, 627
- charging and gauging kit, 625
filter
- boom filter, 54
- vacuum filter, 54
filter change, 631
icons, 13
A2
Index
Index
K
KEP, piston end--of--travel positioning, 645
measuring the wall thickness, machines with S transfer

tube, 681
module control cabinet, 316
leavings, 551, 561
oil cooler, troubleshooting, 712
leveling bubble, 525
open gear lubrication, 68
Liability, Exclusion, 2 9
operating procedures
- cable remote control setup, 520
- cleaning the unit, 550
- outriggers setup, 523
- pre--operation inspection, 57
- preliminary information, 52
- pumping concrete with the emergency stroke kit, 572
- radio remote control setup, 522
- teardown, 565
- unit setup, 59
Lifting loads, 2 5
loading, 48
lubricant analysis, 69
lubricants (recommended), 610
lubrication
- grease, 68
- M 36Z placing boom, 687
- S transfer tube, 655
- TRDI 70 boom pedestal, 689
M
M 36Z, lubrication, 687
machine rating plate, 33
Maintenance cards
- Replacing the S transfer tube, 6 57
- S transfer tube wear parts, 6 57
maintenance cards
- changing the hydraulic fluid, 617
- delivery piston replacement with KEP, 645
- filter change, 631
- function checks, 623
- hoses, 639
- lubricating the M 36Z placing boom, 687
- lubricating the S transfer tube, 655
- lubricating the TRDI 70 boom pedestal, 689
- measuring the wall thickness (machines with S transfer
tube), 681
- performing maintenance on the accumulator, 625
- replacing the delivery line, 691
- vacuum meter, 643
- visual checks, 615
maintenance intervals, 62
maintenance procedures
- adjusting accumulator pressure, 629
- checking accumulator pre--charge pressure, 628
- replacing accumulator bladder, 630
Index
output controller, emergency operation, 349

outriggers
- setup, 523
- snaplock, 524, 569
- temperature--related cylinder movements, 531
overview diagram, 36Z, 32
P
personnel qualifications, 22
piston end--of--travel positioning, KEP, 645
profiled ring joint, 66
prohibited activities, 527
proximity switch, 336
- connector with LEDs, 338
- function check, 53
proximity switch junction box, 336
pump, troubleshooting, 73, 79, 713
pump functions, 53
- stroke length, 53
- stroke time, 53
- switchover, 53
pumping operations, 319, 540
- agitator hopper, 541
- blockages, 546
- breaks in pumping, 545
- calm pumping, 542
A3
Index
cooling, 547
cooling, additional, 547
damping valve, 543
favorable boom position, 542
hand signals, 533
overheating, 547
pumping, 544
restarting, 548
starting pumping, 544
sucking in air, 541
R
radio remote control
- receiver, 330
- setup, 522
- transmitter, 328
- troubleshooting, 79, 712
range diagram, 36Z, 35
rating plate
- boom, 34
- machine, 33
Reaches, Extending, 2 7
remote control, 520
replacing, accumulator bladder, 630
retaining rope, 353
S
S transfer tube
- cleaning, 561
- lubrication, 655
- Replacing, 6 57
- Wear parts, 6 57
safe clearance from pits, 510

space requirement, 512
support block, 515
supporting ground, 513
table of timber block lengths, 516
timber blocks, 515
sinking of the boom, 532

- cooling of the hydraulic fluid, 531
snaplock, outriggers, 524, 569
space requirement, 512
S transfer tube, measuring the wall thickness, 681
summary of the components, 32
support area, table of timber block lengths, 516
support block, 515
supporting ground, 513
symbols, 13
symbols for the control system, 38
- boom, 314
- concrete pump, 38, 39
- electrical system, 311, 312
- engine, 310
- hydraulic system, 313
- outriggers, 313
T
teardown, 565
technical data, 33
- centralized lubrication system, 323
technical description, flushing water pump, 350
thunderstorms, 528
safety regulations, 21, 22
tightening torques
- flared screwed joint, 66
- general, 64
service operation, 319
timber blocks, 515, 516
setting up, 57
- cable remote control system, 520
- outriggers, 523
- radio remote control system, 522
- unit, 59
towing, 44
setup site
- calculation examples of minimum clearance from pits,
511
- corner bearing load, 514
- danger zone, 512
- minimum clearance from pits, 59
A4
transfer tube
transfer tube damping, 347
transmission oil, 68
transport position, retracting the outriggers, 569
travel
- driving, 41
- towing, 41
Index
Index
TRDI 70, lubrication, 689

truck superstructure, cleaning, 564
U
uncontrolled boom movements, 532
Use contrary to the designated use, 2 5
V
vacuum meter, venting, 643
vibrator, 354
visual checks, 615
W
wash--out adapter, 553
water hose, marking, 555
water pump, 346
wind, 528
working range, impermissible working range, boom,
539
Index
A5

Manual Operating &amp; Maintenance Instructions BSF 36-4.12L

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Operating Instructions

Guide to the Operating Instructions . 11

Icons and symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Use contrary to the designated use . . . . . . . . . . . . . . . . . . .

General Technical Description . . . . . 31

36Z Overview Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Machine Rating Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Boom Rating Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

36Z Range Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Description of the Functions . . . . . . . . . . . . . . . . . . . . . . . . .

Symbols for the Control System . . . . . . . . . . . . . . . . . . . . . . 38

Concrete Pump (Part 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical Control Devices . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Control Devices . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hand Signals for Boom and Pumping Operations . . . . . . 533

Extending the 36Z 4 - Section Boom . . . . . . . . . . . . . . . . . . . 534

Pumping Concrete with the Emergency Stroke Kit . . . . . 572

General Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Recommended Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . 610

Visual Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 615

Changing the Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . 617

Function Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623

Performing Maintenance on the Accumulator . . . . . . . . .

Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 631

Vacuum Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 643

Change of Delivery Piston with KEP . . . . . . . . . . . . . . . . . . 645

Lubricating the S Transfer Tube . . . . . . . . . . . . . . . . . . . . . . 655

Measuring the Wall Thickness

Lubricating the M 36Z Placing Boom . . . . . . . . . . . . . . . . . 687

Lubricating the Boom Pedestal (TRDI 70) . . . . . . . . . . . . . 689

Replacing the Delivery Line . . . . . . . . . . . . . . . . . . . . . . . . . . 691

Guide to the Operating Instructions

Guide to the Operating Instructions

Guide to the Operating Instructions

Icons and symbols

The following icons and symbols are used in the Operating

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

Guide to the Operating Instructions

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

Guide to the Operating Instructions

Guide to the Operating Instructions

2.1 Personnel Qualifications

2.2 Safety Regulations

Only qualified personnel must be allowed to operate, repair, or

All personnel operating, assembling, transporting, or maintaining a

Use contrary to the

The placing boom must never be used for lifting loads.

Extending the end hose is not permitted.

End hose with spout

Extending the reach

It is prohibited to attach an extension (eg freely suspended crossbeam) to the

It is forbidden to stand on the placing boom

We state here expressly that Putzmeister accepts no liability for damage

General Technical Description

36Z Overview Diagram

Machine Rating Plate

Boom Rating Plate

36Z Range Diagram

Description of the Functions

Symbols for the Control System

Electrical Control Devices

Hydraulic Control Devices

3.10 Other Components

General Technical Description

Manual Operating & Maintenance Instructions BSF 36-4.12L

Manual Operating & Maintenance Instructions BSF 36-4.12L