Sect. 2 Operating Instructions 2106T5571

Operating Instructions
for machine operator and maintenance staff

always keep by the machine
Translation of the original instructions
Stationary concrete pump BSA 1005 D4F
Machine no. 2106T5571

214490294
2021-12-20
The paper on which this document is printed is 100% chlorine-free © Putzmeister Concrete Pumps GmbH 2021
Putzmeister Concrete Pumps GmbH +49−7127−599−0 pmw@pmw.de
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en Translation of the original instructions
ar ‫ترجمة دليل التشغيل الأصلي‬
bg Превод на оригиналното „Ръководство за работа“
cs Překlad originálního návodu k obsluze
da Oversættelse af den originale driftsvejledning
de Übersetzung der Originalbetriebsanleitung
el Μετάφραση του πρωτότυπου των οδηγιών λειτουργίας
es Traducción del manual de instrucciones original
et Originaalkasutusjuhendi tõlge
fi Alkuperäisen käyttöohjeen käännös
fr Traduction de la notice originale
hr Prijevod originalnog priručnika za rad
hu Az eredeti üzemeltetési utasítás fordítása
it Traduzione delle istruzioni per l'uso originali
ja 取扱説明書原本の翻訳
lt Naudojimo instrukcijos originalo vertimas
lv Oriģinālās lietošanas instrukcijas tulkojums
nl Vertaling van de originele handleiding
no Oversettelse av original bruksanvisning
pl Tłumaczenie oryginalnej instrukcji eksploatacji
pt Tradução das Instruções de funcionamento originais
ro Traducere a instrucţiunilor de funcţionare originale
ru Перевод оригинальной инструкции по эксплуатации
sk Preklad originálneho návodu na obsluhu
sl Prevod originalnih navodil za uporabo
sr Prevod originalnog uputstva za upotrebu
sv Översättning av instruktionsbok i originalutförande
tr Orijinal kullanım kılavuzunun tercümesi
zh 原始操作说明翻译
214490294_2021-12-20_en Operating Instructions

Operating Instructions 214490294_2021-12-20_en
Table of contents 1.
2.
3.
...
Table of contents
1 Guide to the Operating Instructions ........................................ 1—1

1.1 Foreword ......................................................................................................................... 1 —3
1.2 Icons and symbols .......................................................................................................... 1 —4

1.2.1 Layout of warning notices ............................................................................................... 1—5
2 Safety regulations ................................................................... 2—1

2.1 Definition of terms ........................................................................................................... 2 —3
2.1.1 Machine ........................................................................................................................... 2—3
2.1.2 Concrete pump ................................................................................................................ 2—3
2.1.3 Arm assembly ................................................................................................................. 2—3
2.1.4 Placing boom .................................................................................................................. 2—3
2.1.5 Base structure ................................................................................................................. 2—3
2.1.6 Truck mixer ..................................................................................................................... 2—4
2.1.7 Delivery line systems ...................................................................................................... 2—4
2.1.8 End hose ......................................................................................................................... 2—4
2.1.9 Manufacturer ................................................................................................................... 2—4
2.1.10 Operator .......................................................................................................................... 2—4
2.1.11 Machine operator ............................................................................................................ 2—4
2.1.12 Hoseman ......................................................................................................................... 2—4
2.1.13 Signaller and other auxiliary personnel ........................................................................... 2—5
2.1.14 Truck mixer driver ........................................................................................................... 2—5
2.1.15 Subject expert ................................................................................................................. 2—5
2.1.16 Qualified personnel ......................................................................................................... 2—5
2.1.17 After Sales Service personnel ......................................................................................... 2—5
2.1.18 Maintenance .................................................................................................................... 2—5
2.1.19 Place of work, working area, danger zone ...................................................................... 2—6
2.2 Designated use ............................................................................................................... 2 — 10

2.2.1 Retesting (safety inspection) ........................................................................................... 2 — 11
2.2.2 Inspection intervals for retesting ..................................................................................... 2 — 11
2.3 Improper use ................................................................................................................... 2 — 12

2.3.1 Transporting goods ......................................................................................................... 2 — 12
2.3.2 Lifting loads ..................................................................................................................... 2 — 13
2.3.3 Removing obstacles ........................................................................................................ 2 — 13
2.3.4 Extending the reach ........................................................................................................ 2 — 13
2.3.5 Extending the placing boom and end hose ..................................................................... 2 — 13
2.3.6 Impermissible end hose .................................................................................................. 2 — 14
2.3.7 Impermissible working area ............................................................................................ 2 — 14
2.3.8 Climbing the placing boom .............................................................................................. 2 — 15
2.3.9 Highpressure delivery ..................................................................................................... 2 — 15
214490294_2021-12-20_en Operating Instructions A—1

1. Table of contents
2.
3.
...
2.3.10 Accessories and attachments ......................................................................................... 2 — 15

2.3.11 Changes to the machine ................................................................................................. 2 — 15
2.4 Exclusion of liability ......................................................................................................... 2 — 16
2.5 Personnel ........................................................................................................................ 2 — 16

2.5.1 Requirements .................................................................................................................. 2 — 16
2.5.2 Qualifications ................................................................................................................... 2 — 17
2.5.3 Responsibility of the machine operator ........................................................................... 2 — 17
2.6 Operating Instructions, operating procedures and other regulations .............................. 2 — 17

2.6.1 Operating Instructions ..................................................................................................... 2 — 17
2.6.2 Operating procedures ..................................................................................................... 2 — 18
2.6.3 Other regulations ............................................................................................................. 2 — 19
2.7 Personal protective equipment ........................................................................................ 2 — 19
2.8 Before working with the machine .................................................................................... 2 — 21

2.8.1 Checking that the machine is ready for operation ........................................................... 2 — 21
2.8.2 Rendering the machine ready for operation .................................................................... 2 — 21
2.9 Danger due to high voltage ............................................................................................. 2 — 22

2.9.1 High-voltage lines ............................................................................................................ 2 — 22
2.9.2 Discharge voltage pattern ............................................................................................... 2 — 22
2.9.3 Clearances ...................................................................................................................... 2 — 22
2.9.4 Highvoltage warning devices .......................................................................................... 2 — 24
2.9.5 Procedure in the event of a flash over ............................................................................ 2 — 24
2.9.6 Earthing in the event of electrostatic charging ................................................................ 2 — 25
2.9.7 Earthing on construction sites with special installations .................................................. 2 — 25
2.10 Stationary machines ........................................................................................................ 2 — 25

2.10.1 Setup site ........................................................................................................................ 2 — 25
2.10.2 Stationary placing booms ................................................................................................ 2 — 26
2.10.3 Lifting machines and components ................................................................................... 2 — 26
2.10.4 Loading and transporting ................................................................................................ 2 — 26
2.11 Mobile machines ............................................................................................................. 2 — 27

2.11.1 Setup site ........................................................................................................................ 2 — 27
2.11.2 Supporting ground ........................................................................................................... 2 — 28
2.11.3 Corner bearing loads ....................................................................................................... 2 — 29
2.11.4 Supports .......................................................................................................................... 2 — 29
2.11.5 Driving ............................................................................................................................. 2 — 31
2.11.6 Towing ............................................................................................................................. 2 — 32
2.11.7 Loading ........................................................................................................................... 2 — 32
2.12 Placing booms ................................................................................................................. 2 — 33

2.12.1 Unfold placing boom ....................................................................................................... 2 — 33
2.12.2 End hose ......................................................................................................................... 2 — 35
2.12.3 Guiding the end hose ergonomically ............................................................................... 2 — 36
2.12.4 Connecting drills .............................................................................................................. 2 — 36
A—2 Operating Instructions 214490294_2021-12-20_en

2.
3.
...
2.12.5 Procedure in storms ........................................................................................................ 2 — 36

2.12.6 Concreting in cold weather .............................................................................................. 2 — 37
2.13 Delivery line systems ...................................................................................................... 2 — 37

2.13.1 Suitable delivery lines ..................................................................................................... 2 — 37
2.13.2 Securing delivery lines .................................................................................................... 2 — 38
2.13.3 Leak tightness and blockages ......................................................................................... 2 — 38
2.13.4 Opening delivery lines ..................................................................................................... 2 — 39
2.13.5 Clearance to delivery lines .............................................................................................. 2 — 39
2.13.6 Securing the delivery lines .............................................................................................. 2 — 39
2.13.7 Continuation delivery lines .............................................................................................. 2 — 39
2.13.8 Devices for shutting off, diverting and cleaning ............................................................... 2 — 40
2.14 Pumping operations ........................................................................................................ 2 — 40

2.14.1 Place of work ................................................................................................................... 2 — 40
2.14.2 Safety .............................................................................................................................. 2 — 40
2.14.3 Remote control ................................................................................................................ 2 — 41
2.14.4 Moving machine components and hot surfaces .............................................................. 2 — 41
2.14.5 Constant observation of the machine .............................................................................. 2 — 42
2.14.6 Truck mixer ..................................................................................................................... 2 — 42
2.15 Cleaning .......................................................................................................................... 2 — 42

2.15.1 General ........................................................................................................................... 2 — 42
2.15.2 Cleaning agents .............................................................................................................. 2 — 43
2.15.3 Cleaning with compressed air ......................................................................................... 2 — 44
2.15.4 Protection against water .................................................................................................. 2 — 46
2.15.5 Post-cleaning procedure ................................................................................................. 2 — 46
3 General technical description ................................................. 3—1

3.1 Overviews ....................................................................................................................... 3 —3
3.2 Safety equipment ............................................................................................................ 3 —5

3.2.1 Overview ......................................................................................................................... 3—5
3.2.2 Safety components ......................................................................................................... 3—6
3.2.3 Safety-related parts (SRPs) ............................................................................................ 3—6
3.2.4 Plates .............................................................................................................................. 3—8
3.2.5 EMERGENCY STOP function ......................................................................................... 3—8
3.2.6 Agitator safety cutout ...................................................................................................... 3 — 11
3.2.7 Grille ................................................................................................................................ 3 — 16
3.3 General conditions for using the machine ....................................................................... 3 — 17

3.3.1 Service life ....................................................................................................................... 3 — 17
3.3.2 Site of use ....................................................................................................................... 3 — 18
3.3.3 Operating altitude ............................................................................................................ 3 — 18
3.3.4 Operating temperature .................................................................................................... 3 — 18
3.4 Machine rating plate ........................................................................................................ 3 — 19

2.
3.
...
3.5 Sound pressure level/sound power level ........................................................................ 3 — 20

3.5.1 Sound pressure level ...................................................................................................... 3 — 20
3.6 Electromagnetic compatibility (EMC) .............................................................................. 3 — 20
3.7 Putzmeister Connected Services .................................................................................... 3 — 21

3.7.1 Remote Service ............................................................................................................... 3 — 21
3.7.2 Machine Cockpit .............................................................................................................. 3 — 21
3.8 Exhaust after treatment ................................................................................................... 3 — 21

3.8.1 Function .......................................................................................................................... 3 — 22
3.8.2 Regeneration ................................................................................................................... 3 — 22
3.8.3 Starting regeneration ....................................................................................................... 3 — 23
3.9 Colour definition – LEDs in the button ............................................................................. 3 — 24
3.10 Control cabinet ................................................................................................................ 3 — 25
3.11 Core pump operating panel ............................................................................................. 3 — 26
3.12 Display ............................................................................................................................ 3 — 28
3.13 Software .......................................................................................................................... 3 — 29

3.13.1 DEF tank ......................................................................................................................... 3 — 29
3.13.2 Main menu ...................................................................................................................... 3 — 30
3.13.3 “User settings” menu ....................................................................................................... 3 — 33
3.13.4 “Core pump” menu .......................................................................................................... 3 — 34
3.13.5 “Motor” menu ................................................................................................................... 3 — 37
3.13.6 “Inputs and outputs” menu .............................................................................................. 3 — 39
3.13.7 “Operating data” menu .................................................................................................... 3 — 41
3.13.8 Messages ........................................................................................................................ 3 — 42
3.14 Cable remote control ....................................................................................................... 3 — 45

3.14.1 Structure .......................................................................................................................... 3 — 45
3.14.2 Safely using the remote control ....................................................................................... 3 — 47
3.15 Core pump ...................................................................................................................... 3 — 48

3.15.1 Structure .......................................................................................................................... 3 — 48
3.15.2 Function .......................................................................................................................... 3 — 48
3.15.3 Reversal .......................................................................................................................... 3 — 49
3.15.4 Changeover ..................................................................................................................... 3 — 49
3.15.5 Water box ........................................................................................................................ 3 — 50
3.15.6 Agitator ............................................................................................................................ 3 — 53
3.15.7 Vibrator ............................................................................................................................ 3 — 55
3.15.8 Magnetic switch distributor casing .................................................................................. 3 — 56
3.15.9 Magnetic switch connector .............................................................................................. 3 — 58
3.16 Centralised lubrication system ........................................................................................ 3 — 60

3.16.1 Structure .......................................................................................................................... 3 — 60
3.16.2 Function .......................................................................................................................... 3 — 60

2.
3.
...
3.16.3 Maintaining the centralised lubrication system ................................................................ 3 — 61

3.16.4 Filling the lubricant reservoir ........................................................................................... 3 — 61
3.16.5 Additional lubrication procedure ...................................................................................... 3 — 62
4 Transport, support and connection ......................................... 4—1

4.1 Transporting .................................................................................................................... 4 —3
4.1.1 Loading ........................................................................................................................... 4—3
4.1.2 Driving ............................................................................................................................. 4—5
4.2 Supporting the machine .................................................................................................. 4 —5

4.2.1 Checking the setup site ................................................................................................... 4—5
4.2.2 Support structure ............................................................................................................. 4 — 10
4.2.3 Extend supports .............................................................................................................. 4 — 11
4.2.4 Retracting the supports ................................................................................................... 4 — 16
5 Operation ................................................................................ 5—1

5.1 Test run ........................................................................................................................... 5 —3
5.2 Starting up ....................................................................................................................... 5 —3

5.2.1 Checking the machine for damage ................................................................................. 5—3
5.2.2 Draining the hydraulic fluid reservoir ............................................................................... 5—5
5.2.3 Checking functional fluids ............................................................................................... 5—6
5.2.4 Switching on the machine ............................................................................................... 5—7
5.2.5 Warming up the hydraulic fluid ........................................................................................ 5—8
5.2.6 Deactivating the EMERGENCY STOP ........................................................................... 5—8
5.2.7 Deactivating the agitator safety cutout ............................................................................ 5—9
5.3 Checking the functions .................................................................................................... 5 —9

5.3.1 Checking the EMERGENCY STOP function ................................................................... 5 — 10
5.3.2 Checking the agitator safety cutout ................................................................................. 5 — 11
5.3.3 Checking the pump functions .......................................................................................... 5 — 13
5.3.4 Checking the hydraulic fluid filters ................................................................................... 5 — 14
5.4 Hand signals for pumping operations .............................................................................. 5 — 16

5.4.1 EMERGENCY STOP hand signal ................................................................................... 5 — 17
5.4.2 Hand signal for stopping ................................................................................................. 5 — 17
5.4.3 Hand signal for increasing output/start of delivery .......................................................... 5 — 18
5.4.4 Hand signal for reducing output ...................................................................................... 5 — 18
5.4.5 Hand signal for reverse pumping .................................................................................... 5 — 19
5.4.6 Hand signal for stopping the pump ................................................................................. 5 — 19
5.5 Filling the water box ........................................................................................................ 5 — 19
5.6 Pumping .......................................................................................................................... 5 — 20

5.6.1 Dangers during pumping ................................................................................................. 5 — 20
5.6.2 Notes on correct pumping ............................................................................................... 5 — 21

2.
3.
...
5.6.3 Damping valve ................................................................................................................ 5 — 21

5.6.4 Mixing together ................................................................................................................ 5 — 22
5.6.5 Operating the agitator ..................................................................................................... 5 — 22
5.6.6 Starting to pump .............................................................................................................. 5 — 23
5.6.7 Starting the pumping process ......................................................................................... 5 — 25
5.6.8 Checking the condition of the machine ........................................................................... 5 — 25
5.6.9 Breaks in pumping .......................................................................................................... 5 — 25
5.6.10 Rectify any faults ............................................................................................................. 5 — 26
5.7 Cleaning .......................................................................................................................... 5 — 30

5.7.1 Observe the notes on cleaning ....................................................................................... 5 — 32
5.7.2 Cleaning preparations ..................................................................................................... 5 — 32
5.7.3 Using concrete residue ................................................................................................... 5 — 37
5.7.4 Clean the delivery line ..................................................................................................... 5 — 38
5.7.5 Cleaning the core pump .................................................................................................. 5 — 51
5.7.6 Cleaning the remote control ............................................................................................ 5 — 58
5.7.7 Cleaning other machine components .............................................................................. 5 — 58
5.8 Storing the machine ........................................................................................................ 5 — 59

5.8.1 Document the measures taken to preserve value ........................................................... 5 — 59
5.8.2 General measures to preserve value .............................................................................. 5 — 59
5.8.3 General measures to preserve the value of the electrical system assembly .................. 5 — 60
5.8.4 General measures to preserve the value of the water assembly .................................... 5 — 61
5.8.5 General measures to preserve the value of the engine assembly .................................. 5 — 61
5.8.6 General measures to preserve the value of the concrete pump assembly ..................... 5 — 61
5.8.7 General measures to preserve the value of the hopper assembly .................................. 5 — 62
Glossary .................................................................................. B—1

Symbols for concrete pumps in accordance with German Mechanical Engineering B—3
Association Standard (VDMA -24119) ............................................................................
Abbreviations and technical terms .................................................................................. B — 11
Index ........................................................................................ C —1

1 Guide to the Operating Instructions
In this chapter you will find notes and information that will help you
use this document. If you have any queries, please write to us in
confidence at the address given below, or contact the relevant
branch or works agency.
Putzmeister Concrete Pumps
Abteilung Kundendienst
Max-Eyth-Straße 10
72631 Aichtal, Germany
Telephone: +49 (0) 7127 599-0
Fax: +49 (0) 7127 599-520
E-mail: services@pmw.de
You can contact the relevant branch or works agency by calling the
following service hotline from a landline in Germany or from any Ger‐
man mobile phone network.
Service hotline tel.: +49 (0) 1805 / 30 18 30
214490294_2021-12-20_en Operating Instructions 1—1

1—2 Operating Instructions 214490294_2021-12-20_en
Guide to the Operating Instructions
1.1 Foreword
These Operating Instructions aim to help you to familiarise yourself
with the machine and make use of its intended applications.
The Operating Instructions contain important information on how to

operate the machine safely, properly and economically. Observing
these instructions helps to avoid danger, to reduce repair costs and
downtimes and to increase the reliability and service life of the ma‐
chine.
The operator undertakes to supplement the Operating Instructions

with the relevant national rules and regulations for accident preven‐
tion and environmental protection.
The Operating Instructions must always be available wherever the

machine is in use.
The Operating Instructions must be read and applied by anyone who

will be carrying out the following work with/on the machine:
● Operation, including setting up, fault rectification in the course of
work, removal of production waste, maintenance and disposal of
fuels and auxiliary materials
● Maintenance (service, inspection, repair)
● Transport
The generally recognised rules of technology for safe and proper

working must be observed in addition to the Operating Instructions
and mandatory rules and regulations for accident prevention in the
country and place of use of the machine.
If you have any questions after reading the Operating Instructions,

you can contact:
● The branch serving you
(or its agents)
● Aichtal Works
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 num‐
ber.
For the purpose of continuous improvement, changes are made at

certain times, meaning that these changes may in some circumstan‐
ces not yet have been taken into account by the time these Operating
Instructions are sent to print.

In the event of any amendment, the copy of the Operating Instruc‐

tions intended for the machine will be replaced in full.
The reproduction, distribution and utilisation of this document as well

as the communication of its contents to others without explicit authori‐
sation is prohibited. Violations will result in a claim for damages. All
rights reserved in the event of the grant of a patent, utility model or
design.
© Putzmeister Concrete Pumps GmbH 1994
1.2 Icons and symbols

The following icons and symbols are used:
Icon/symbol/ Meaning
designation
▶ Individual instruction or alternative step
1. 2. 3. Instructions to be carried out as described in the
specified sequence.
⇒ Intermediate result of multiple steps.
➙ End result of an individual instruction or of multi‐
ple steps.
● Bullet point list – Key words or short sentences
that provide comprehensive information. This in‐
cludes the various options available, enumera‐
tions, lists of components, etc.
Operating ele‐ Operating elements are written in small capitals to
ment make it immediately clear which operating ele‐
ment should be used. The designation is only
written in small capitals in continuous text and in
instructions. Tables and headings are not inclu‐
ded.
Link/cross ref‐ A link/cross reference to related topics. Cross ref‐
erence: erence with page number and heading. If the
(Icons and cross reference is displayed digitally, it acts as a
symbols direct link to a related topic area.
P. 1 — 4)

designation
Fault rectification – Instructions to be carried out
in accordance with fault messages.
View additional steps. For example, “Contact a
qualified electrician”.
✓ The requirements or tools outlined below must be
met or available.
Tests or inspections have been passed.
This indicates a tip, helpful note or additional in‐
formation regarding machine maintenance, envi‐
ronmental protection, etc.
1.2.1 Layout of warning notices
WARNING
Type and cause of risk
Consequences of not observing the risk.
▶ What to do in order to provide a remedy or avoid the risk.
Signal words
The signal word is chosen in accordance with the ANSI Z535.6:2011

safety standard.
The following signal words are used:
DANGER
Indicates a dangerous situation in which an accident resulting in se‐
rious injuries and/or death may occur. Highest level of risk.
▶ After identifying the risk, instructions are set out which are inten‐
ded to avoid or remedy the risk.

WARNING
rious or fatal injuries may occur.
CAUTION
There is a risk of injury to the entire body, however there is no risk
of serious or fatal injuries.
NOTICE
Risk of damage to the machine. There is no risk of injury.

2 Safety regulations
These safety regulations correspond to the “Terms, definitions, re‐
quirements” and “Starting up and working with the machine” sections
in the VDMA (German Engineering Federation) brochure “Safety
manual for concrete delivery and placing machines”.
Here you will find a summary of the most important safety regulations.
This chapter is therefore particularly useful for providing initial and ba‐
sic instruction for new employees.
Special safety regulations may be necessary for some tasks.

These special safety regulations will only be found in the descrip‐
tion of the particular task.
We include here a listing of regulations and safety standards for

your information:
● DIN EN 12001:2012, Conveying, spraying and placing ma‐
chines for concrete and mortar
● DIN EN 60204-1:2014, Safety of machinery – electrical equip‐
ment on machines
● DIN EN ISO 12100:2011, Safety of machinery

Safety regulations
2.1 Definition of terms

The terms used in this Safety Manual are explained below, along with
descriptions of the requirements placed on specific groups of people.
2.1.1 Machine
For the purposes of this Safety Manual, concrete delivery and placing
machines are defined as:
● Truck-mounted concrete pumps (an ensemble of truck and con‐
crete pump with and without placing boom). The safety regulations
issued by the truck manufacturer also apply to the truck.
● Truck mixer concrete pump (an ensemble of truck mixer, concrete
pump and placing boom). The safety regulations issued by the
truck mixer manufacturer and by the truck manufacturer also apply
to truck mixer concrete pumps.
● Stationary concrete pumps
● Stationary placing systems (an ensemble of placing boom and
base structure)
2.1.2 Concrete pump
For the purposes of this Safety Manual, concrete pumps are defined
as devices which are designed to deliver concrete to placement sites
via pipes or hoses.
2.1.3 Arm assembly
Arm assembly is a synonym for placing boom and can be used inter‐
changeably.
2.1.4 Placing boom
For the purposes of this Safety Manual, placing booms are defined as
powered, slewable devices consisting of one or more swinging or
folding sections for guiding the delivery line.
2.1.5 Base structure
For the purposes of this Safety Manual, base structures are defined
as equipment which is designed to hold a stationary placing boom to
give the latter the required stability.

Safety regulations
2.1.6 Truck mixer
For the purposes of this Safety Manual, truck mixers are defined as
vehicles with mixing equipment for transporting concrete.
2.1.7 Delivery line systems
For the purposes of this Safety Manual, delivery line systems are de‐
fined as self-contained pipes or hoses in which concrete is pumped
from the concrete pump to the placement site. Devices for shutting
off, diverting or cleaning delivery lines can be integrated into delivery
line systems.
2.1.8 End hose
For the purposes of this Safety Manual, end hose is defined as the
hose that is fitted on the placing boom at the end of the delivery line
for distributing the concrete. There must be no couplings, spouts, dis‐
charge stops or other items fixed to the outlet end of the end hose un‐
less they are approved by the manufacturer.
2.1.9 Manufacturer
Any natural or legal person that markets a machine or incomplete ma‐

chine that is dealt with in this Safety Manual.
2.1.10 Operator
Authorised representative of the owner of the concrete pumps and/or

placing booms. The operator is responsible for the use of these ma‐
chines.
2.1.11 Machine operator
Persons trained in and charged with the operation of concrete pumps

and placing booms.
2.1.12 Hoseman
Persons instructed by the site management in how an end hose is

guided. Hosemen must be able to independently evaluate all danger‐
ous situations which may occur in the area of the end hose and react
according to the situation.

Safety regulations
2.1.13 Signaller and other auxiliary personnel
Persons instructed by the site management to help the machine oper‐

ator in his work if the latter is unable to observe all areas of operation
and danger zones. Signallers must be able to independently evaluate
all dangerous situations which may occur when working with a con‐
crete pump and/or placing boom and react according to the situation.
The signaller must have a suitable means of communication with the
machine operator.
2.1.14 Truck mixer driver
Persons who supply the concrete pump with concrete from a truck
mixer. Truck mixer drivers must be instructed by the machine opera‐
tor to operate the operating elements on the concrete pump provided
for their use. Truck mixer drivers must be able to independently eval‐
uate all dangerous situations which may occur when working in the
area of the hopper of a concrete pump and react according to the sit‐
uation.
2.1.15 Subject expert
For the purposes of this Safety Manual, a subject expert is defined as

a person who, through their professional training, their professional
experience and their recent professional activity, has the required
specialist knowledge to inspect the tools.
2.1.16 Qualified personnel
Persons who have completed specialist training for a particular activi‐

ty which qualifies them to carry out their roles.
2.1.17 After Sales Service personnel
Qualified personnel employed by the manufacturer who are responsi‐

ble in particular for maintenance of the machine.
2.1.18 Maintenance
Maintenance includes all measures required to inspect, maintain and

repair a machine.

Safety regulations
2.1.19 Place of work, working area, danger zone
2.1.19.1 Mobile machines
Figure 1: Example
2.1.19.2 Stationary machines
Figure 2: Example

Safety regulations
Pos. Designation Explanation

1 Place of work (during Machine operator In normal operation, with the remote con‐
pumping operations) trol
2 Hoseman At the end hose in the danger zone
3 Signaller In the machine operator's range of vision
4 Auxiliary personnel As machine operators of the manual
placing system
5 Truck mixer driver At the hopper in the danger zone
6 Working area Permitted Area with a radius of the reach of the
placing boom + end hose length
7 Working area Impermissible The end hose must not be moved back‐
wards beyond the vertical of the placing
boom.
8 Danger zone At the end hose Risk of injury when pumping is started,
during pumping operations, when remov‐
ing a blockage and during cleaning pro‐
cedures. The diameter of the danger
zone is twice the end hose length.
9 Danger zone Beneath the placing boom Risk of injury from falling items
10 Danger zone Area of the support legs Risk of crushing when setting up or dis‐
and feet or area of the mantling the machine
base structure
11 Danger zone On the machine Any presence on or below the machine
when the pump is in operation is prohibi‐
ted
12 Danger zone On the hopper Risk of injury during cleaning procedures
and when the hopper is being filled using
a truck mixer
13 Danger zone Area of the delivery line Hazard posed if lines burst, risk of injury
systems from crushing or shearing, particularly
with gate valves
14 Structure or area being concreted Example

Safety regulations
2.1.19.3 Place of work
The place of work is the area in which people must remain in order to
carry out the work.
Place of work – machine operator
The machine operator's place of work is with the remote control when
the pump is in operation. The place of work must be selected so as to
allow visual contact with the placement site and the truck mixer driver,
and so that the working area can be observed at the same time. A
signaller must otherwise be used.
The machine operator's place of work is with the machine when this
is being set up or prepared for driving.
Place of work – hoseman
The hoseman's place of work is within the danger zone of the end
hose, but not beneath the placing boom. This requires a greater level
of caution. The hoseman and machine operator must have visual
contact.
Place of work – truck mixer driver
The truck mixer driver's place of work is in the danger zone of the
hopper and at operating elements for the agitator and truck mixer.
This requires a greater level of caution. The truck mixer driver and
machine operator must have visual contact.
2.1.19.4 Working area
The working area is the area in which work is carried out with or on
the machine. Parts of the working area can become danger zones de‐
pending on the operation being carried out and the position of the
placing boom.
The working area must be secured and clearly identified. Suitable

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

Safety regulations
Impermissible working area
Because of their high manoeuvrability, some placing booms can also

be shifted into positions for which they are not designed. This may
overload or damage the placing boom. Placing booms must therefore
only be moved within the permitted working area. (Impermissible
working area P. 2 — 14)
2.1.19.5 Danger zone
The danger zone is the area surrounding the machine, in which peo‐
ple may be at risk of injury from movements required by the work.
The danger zone varies within the working area and depends on the
activity being carried out and the position of the placing boom, if one
is present. Danger zones must be secured and clearly identified. The
machine operator must be capable of seeing the danger zone at all
times and under all circumstances. If necessary, he must appoint a
signaller to supervise the danger zone.
Depending on the working situation, places of work may occasionally

fall within the danger zone, especially the place of work of the hose‐
man and the truck mixer driver. If a place of work falls within the dan‐
ger zone, increased caution is required and suitable personal protec‐
tive equipment is prescribed. Persons who are authorised to be pres‐
ent in such a place of work must use their own discretion to assess
dangerous situations and be able to react according to the situation.
The machine operator is responsible for safety in the danger zone of

the machine whilst the machine is in use.
The machine operator must stop work immediately and press the
EMERGENCY STOP button if an unauthorised person enters the
danger zone.
Support legs and support feet
There is a risk of crushing in the swingout and extension zone for the
supports.
Placing boom
The danger zone when working with the placing boom is the zone
over which the placing boom is slewed. In this area there is a risk of
injury from falling concrete and delivery line components.

Safety regulations
Machine
All the time the vehicle is in operation, there is a risk of injury on and
below the machine from moving parts and bursting delivery lines or
hydraulic hoses, as well as a risk of falling on slippery surfaces or
steps.
End hose
The danger zone when pumping is started, during pumping opera‐

tions, when removing a blockage and during cleaning procedures is
the area around the end hose in which the end hose may swing out.
The diameter of the danger zone is twice the end hose length.
Hopper
In the area of the hopper, there is a risk of becoming trapped between

the truck mixer and the hopper and of being sprayed with concrete.
There is a risk of being crushed and of injury by shearing from the
transfer tube. There is a risk of becoming caught in the rotating agita‐
tor.
Delivery line systems
In the area around the delivery line systems there is a risk of injury
from the delivery line bursting if there is an abrupt rise in pressure.
There is a risk of crushing and injury by shearing with devices integra‐
ted in delivery line systems.
2.2 Designated use

The machine must only be operated as intended and in technically
perfect condition. All protective and safetyoriented devices, particular‐
ly removable protective devices and EMERGENCY STOP devices,
must be available and fully functional.
The machine is designed exclusively for the delivery and placing of

concrete up to a bulk density of 2400 kg/m3. It must only be used for
pumping operations on construction sites. The maximum delivery
pressure must not exceed that specified on the rating plate or in the
check book.
2 — 10 Operating Instructions 214490294_2021-12-20_en

Safety regulations
You must also observe the Operating Instructions and comply with
the intervals and conditions for inspections (particularly retesting) and
maintenance work in order to operate the machine within the limits of
its proper use.
2.2.1 Retesting (safety inspection)
After initial commissioning of the machine, the operational safety of

the machine must be checked regularly by a subject expert. The in‐
spection intervals depend on the age of the machine. The older the
machine, the greater the probability of damage. For this reason, regu‐
lar retesting of the machine, appropriate to its age, must be carried
out in order to detect damage in good time. Retesting should be car‐
ried out in accordance with the inspection intervals listed below.
Retesting must consist of the following:

● Retesting of the condition of the components and equipment with
regard to the formation of cracks, damage, wear, corrosion and
other changes;
● Retesting of the completeness and effectiveness of the safety
equipment;
● Retesting to find out whether any defects which are found during
the tests mentioned above and which could affect safety have
been adequately rectified.
Retesting must include components which are used in conjunction

with the machine (in particular, delivery line components and acces‐
sories).
Furthermore, information provided by the manufacturer to the opera‐

tor with reference to special instructions for maintenance and inspec‐
tion must be observed.
2.2.2 Inspection intervals for retesting
The inspection intervals are fixed as follows:

● Machines up to and including 5 years old:
Inspect after every 1000 operating hours or 1 year, whichever is
soonest. The interval is repeated after every retest.
● Machines more than 5 years old:
214490294_2021-12-20_en Operating Instructions 2 — 11

Safety regulations

● Machines more than 10 years old:
The day of initial commissioning in accordance with the handover re‐

port and the machine's operating hours meter are definitive for the in‐
tervals. This operating hours meter records the hours of pumping op‐
erations. The operating hours meter must always be kept in good
working order. It must not be tampered with. For machines without an
operating hours meter, the operating hours must be recorded in a
traceable form in writing.
Retesting must be arranged by the operator. The results of retesting

must be entered in the check book and signed. The check book must
always be kept with the machine and must be produced upon the re‐
quest of the national supervisory bodies.
Notwithstanding national legislation, the operator can be liable in the

event of damage, if it is proved that the damage has arisen as a con‐
sequence of regular retesting not being properly carried out.
If retesting is not carried out, the manufacturer will assume that the
machine has been shut down. When the machine is restarted, retest‐
ing must be carried out.
2.3 Improper use

Improper use is defined as use which is not described in or goes be‐
yond that described in the “Designated use”, (Designated use
P. 2 — 10) section. The manufacturer accepts no liability for damage
resulting from such use. Some examples of conceivable improper
uses are given below.
2.3.1 Transporting goods
The machine must not be used for the transport of goods, except for
carrying the accessories used for the machine, such as pipes, hoses,
etc. The maximum permissible gross weight may not be exceeded.

Safety regulations
2.3.2 Lifting loads
The placing boom must never be used for lifting loads.
2.3.3 Removing obstacles
The placing boom must not be used under any circumstances to re‐
move obstacles. This would overload the placing boom, causing dam‐
age and endangering people.
2.3.4 Extending the reach
It is forbidden to attach an extension to the end hose or boom tip of

the placing boom (e.g. freely suspended transition liner) in order to
extend the reach or in order to be able to pump “around corners”.
Since the placing boom and the lifting equipment for the extension
have differing pivot points and modes of control, it is not possible to
co-ordinate their movements.
2.3.5 Extending the placing boom and end hose
Extension of the placing boom and end hose beyond the length speci‐
fied on the rating plate is forbidden.
If the manufacturer defines the weight rather than the length of the
end hose, you can use a reducer pipe with a longer end hose, for ex‐
ample. The quoted gross weight must not be exceeded. (End hose
P. 2 — 35)
When using a longer end hose, the diameter of the danger zone also
increases. (End hose P. 2 — 35)
End hoses with a length of more than 4 m must not be guided by

hand.

Safety regulations
2.3.6 Impermissible end hose
There must be no couplings, spouts, discharge stops or other items

fixed to the outlet end of the end hose unless they are approved by
the manufacturer.
2.3.7 Impermissible working area
During pumping operations, the end hose must not be moved back‐
wards beyond the vertical axis of rotation of the placing boom.

Safety regulations
In addition to this, additional impermissible working areas exist, de‐

pending on the machine model and manufacturer, which are descri‐
bed in the Operating Instructions.
2.3.8 Climbing the placing boom
It is prohibited to climb the placing boom, to stand on top of it or to

misuse it as a working platform or climbing aid.
2.3.9 Highpressure delivery
It is prohibited to deliver concrete at high pressure (delivery pressure

greater than 85 bar) through the delivery line of the placing boom. De‐
livery line elements are marked with the maximum permissible deliv‐
ery pressure. The delivery line and end hose are only suitable for de‐
livery pressures of up to 85 bar until the wear threshold is reached.
For the wear threshold, refer to the Operating Instructions for the ma‐
chine.
2.3.10 Accessories and attachments
It is prohibited to fit accessories and attachments to the machine if

they have not been expressly approved for use on this machine by
the manufacturer.
2.3.11 Changes to the machine
You are not allowed to carry out your own changes to the machine.
Changes must always be approved by the manufacturer.

Safety regulations
2.4 Exclusion of liability

Where the manufacturer's delivery conditions are agreed, liability will
be as described in the provisions there. The manufacturer is not liable
for damage in cases specified there.
Unless the responsibility of the manufacturer, the warranty will be in‐

validated in the following situations in particular:
● use contrary to designated use.
● incorrect operation, maintenance and repair.
● use of spare parts or accessories other than original manufactur‐
er's spare parts and accessories or their equivalents.
● conversions, alterations or modifications to the machine.
● fitting of accessories and attachments not approved by the manu‐
facturer.
● adjustment of safety pressures, speeds of movement, power out‐
puts, speeds of rotation and other settings to values other than
those set in the works.
2.5 Personnel
The operator must ensure that only persons who are qualified or have
received the necessary instruction work on or with the machine. It is
the responsibility of the operator to carry out regular (e.g. annual)
safety briefings for their employees. Suitable training can be reques‐
ted from the machine manufacturer. The operator must clearly define
who is responsible for operation and maintenance of the machine.
The operating company must also ensure that only persons commis‐
sioned to work on the machine do so. In addition, the operator should
provide the necessary personal protective equipment.
2.5.1 Requirements
Persons operating or carrying out maintenance work on the machine

must meet the following requirements:
● They must be aged 18 years or over.
● They must be physically and mentally capable.
● They must be physiologically capable (rested and not under the in‐
fluence of alcohol, drugs or medication).
● They must have been instructed in the operation and maintenance
of the machine.

Safety regulations
● They must have demonstrated their competence to the operator.

● They can be expected to reliably execute the tasks with which they
are charged.
The operating personnel must not wear loose garments or jewellery,

including rings. Long hair which is not tied back must be covered by a
hair net. There is a risk of injury, in particular from being caught or
trapped by moving parts.
All persons working on or with the machine must concentrate on the

task at hand and not be distracted, particularly by smartphones and
music played through headphones.
2.5.2 Qualifications
Persons who are being trained, introduced and instructed in the use
of the machine are only permitted to operate the machine under the
constant supervision of experienced personnel.
If you do not have qualified personnel, suitable workshop equipment,

etc. available, you should commission the manufacturer's After Sales
Department with the maintenance of your machine.
2.5.3 Responsibility of the machine operator
The operator must define the responsibility of the machine operator

(including in respect to national road traffic regulations) and empower
the machine operator to reject instructions from third parties prejudi‐
cial to safety. The machine operator must be able to reject the site of
operations in the event of doubts regarding technical safety.
2.6 Operating Instructions, operating procedures and

other regulations
2.6.1 Operating Instructions
Personnel that are authorised to work on the machine must have read
the Operating Instructions, particularly the “Safety Regulations” sec‐
tion, and the Safety Manual before working with the machine. Read‐
ing the instructions after work has begun is too late. This applies es‐
pecially to persons working only occasionally on the machine, e.g.
during setting up or maintenance.

Safety regulations
As the operator, you must always make sure that the Operating In‐
structions are available. The Operating Instructions and check book
must always be kept to hand at the site of use of the machine (in the
tool compartment or container provided for this purpose).
As the operator, you must have personnel working on the machine

confirm in writing their knowledge, understanding and application of
the Operating Instructions and Safety Regulations and Safety Man‐
ual. At regular intervals of at least once a year, check that personnel
are conscious of safety and the hazards involved in their work and
are taking account of the Operating Instructions.
Personnel entrusted with work on the machine must observe all safe‐
ty instructions and hazard warnings, and must be familiar with the
machine itself. You must practice all the operating procedures descri‐
bed in the Operating Instructions (extending the supports, operating
the placing boom, shifting the placing boom into the driving position,
preparing the vehicle for moving, etc.) under the supervision of a sub‐
ject expert until you are certain you can execute them safely. Ask
questions if there is something you have not understood. Begin oper‐
ating the machine only once you are fully and explicitly familiar with
the layout and significance of all the control and monitoring devices
and the method of operation of the machine.
2.6.2 Operating procedures
The operator must produce operating procedures for their personnel

in accordance with national regulations. These operating procedures
must also contain instructions (including the obligation to provide su‐
pervision and reports) concerning the observance of special opera‐
tional features, particularly in respect of work organization, working
procedures or personnel deployment. Furthermore, reference must
be made to other generally valid legal and otherwise mandatory regu‐
lations relating to accident prevention and environmental protection.
Such regulations may also deal with handling hazardous substances,
the issuing and wearing of personal protective equipment or with na‐
tional road traffic regulations. You should familiarise yourself with the
site of operations and with how to use fire extinguishers. Observe the
firealarm and fire-fighting procedures.

Safety regulations
2.6.3 Other regulations
The current regulations for concrete delivery and placing machines as

issued by:
● The legal authorities in your country
● The national supervisory bodies
● The responsible commercial liability insurance company.
2.7 Personal protective equipment

To reduce the risk to life and limb, personal protective equipment
must be used by the operating personnel whenever necessary or re‐
quired by regulations. Safety helmet, protective gloves and safety
footwear are specified for all persons working at or with the machine.
Personal protective equipment must at least comply with the specified

standards.
Symbol Meaning
Safety helmet
The safety helmet protects your head, e.g.
against falling concrete or parts of the deliv‐
ery line if the lines burst.
(DIN EN 397:2013; Industrial safety helmets)
Safety footwear
Safety footwear protects your feet against fall‐
ing objects and against penetration by projec‐
ting nails.
(DIN EN ISO 20345:2012; Safety footwear for
professional use; category S3)

Safety regulations
Symbol Meaning
Hearing protectors
Hearing protectors protect you against the
noise generated in the vicinity of the machine
when you are standing close to it.
(DIN EN 352-1:2003; Hearing protectors -
General requirements - Part 1: Earmuffs or
DIN EN 352-3:2003; Hearing protectors -
General requirements - Part 3: Earmuffs at‐
tached to an industrial safety helmet)
Protective gloves
Protective gloves protect your hands against
aggressive or chemical substances and
against mechanical effects (e.g. knocks) and
cutting injuries.
(DIN EN 388:2017; Protective gloves against
mechanical risks; classification 1111)
Protective goggles
Protective goggles protect your eyes from in‐
juries due to concrete spatter and other parti‐
cles.
(DIN EN 166:2002; Personal eye protection -
Specifications)

Safety regulations
Symbol Meaning
Safety harness
When working at heights, use climbing aids
and platforms that are intended for this pur‐
pose and comply with the safety regulations
or wear a safety harness. Relevant national
regulations must be observed.
(DIN EN 361:2002; Personal protective equip‐
ment against falls from a height - Full body
harnesses; category III)
Respiratory protection and face mask
Respiratory protection and face masks pro‐
tect you from particles of building materials
that may enter your body through the respira‐
tory passages (e.g. concrete admixtures).
(DIN EN 149:2009; Respiratory protection de‐
vices - Filtering half masks to protect against
particles - Requirements, testing, marking;
classification FFP1)
2.8 Before working with the machine
2.8.1 Checking that the machine is ready for operation
As machine operator, it is your responsibility to check the machine for

external damage and defects before any use of the machine. You
must immediately report any changes (including changes in the work‐
ing characteristics) to the organisation or person responsible. If nec‐
essary, shut the machine down immediately and secure it.
2.8.2 Rendering the machine ready for operation
As machine operator, you are responsible for rendering the machine

ready for operation. This also includes topping up the functional flu‐
ids. Do not fill with fuel in enclosed spaces. Switch off the engine and
the heating. Wipe up spilt fuel immediately. Do not smoke or use a
naked flame when handling fuel.

Safety regulations
Set all the control and monitoring devices to the zero position before
you change the mode of control (control block, control console or re‐
mote control).
Never put the remote control down when the machine is ready for op‐
eration. If this is unavoidable in exceptional cases, you must switch
off the remote control, disconnect it and lock it away.
Never leave the machine when the engine is running or when the en‐
gine could be started by an unauthorised person. If you need to leave
the machine, proceed as follows:
● Switch off the remote control.

● Disconnect the remote control and lock it away.
● Switch off the ignition or the main switch.
● Lock the control cabinet.
2.9 Danger due to high voltage
2.9.1 High-voltage lines
Whenever you touch a high-voltage line, there is a risk of death for all
persons either on the machine or in its vicinity or who are connected
to it (via the remote control, end hose, etc.). A spark can jump across
from a highvoltage line even if you just approach it and this will ener‐
gise the machine and the surrounding area.
2.9.2 Discharge voltage pattern
In the event of a flash over, what is known as a “discharge voltage

pattern” is formed in the vicinity of the machine. The voltage decrea‐
ses from the inside to the outside in this discharge voltage pattern. If
you step inside this discharge voltage pattern, you will bridge different
potentials. This will cause a voltage corresponding to the potential dif‐
ference to flow through your body.
2.9.3 Clearances
Maintain a minimum clearance from highvoltage lines in accordance

with the following table. The minimum clearance is measured in the
horizontal when the placing boom is fully extended.

Safety regulations
Rated voltage [V] Minimum clearance [m]

up to 1 kV 1.0
1 kV up to 110 kV 3.0
110 kV up to 220 kV 4.0
220 kV up to 380 kV 5.0
unknown rated voltage 5.0
The specified clearances are minimum requirements. You must ob‐

serve any greater clearances that may be specified in the country of
use.
When you set a minimum clearance, the possibility of the high-volt‐

age lines and the placing boom swaying in the wind must also be tak‐
en into consideration. You should further note that where air humidity
is high, clearances greater than the minimum clearances shown
above are always necessary.
You must stand as close as possible to the unfolded placing boom if

you wish to correctly estimate the movements of the boom and,
above all, the clearance between the placing boom and obstacles or
high-voltage lines.
The same minimum clearances are necessary when driving under

overhead cables.
In the event that this minimum clearance cannot be maintained under

all possible working positions, the power station responsible must be
contacted and you must have the highvoltage line switched off.
Should you have any doubts, it is better to forgo the use of the plac‐
ing boom and to lay a separate delivery line, for instance.

Safety regulations
2.9.4 Highvoltage warning devices
According to the current rules of engineering, highvoltage warning de‐

vices do not meet a safety standard which enables minimum clearan‐
ces to highvoltage lines that are smaller than the required minimum
clearances to be used. Previous experience has shown that highvolt‐
age warning devices cannot make all situations in working proce‐
dures safe. Flash overs and fatal accidents can occur despite the use
of a highvoltage warning device. You must therefore always maintain
the minimum clearances mentioned above.
2.9.5 Procedure in the event of a flash over
If, despite all precautions, a flash over occurs, stay calm and do not
move (potential differential) or touch anything.
If your machine comes into contact with high-voltage lines:

● Warn people standing outside the area not to approach or touch
the machine.
● Have the power switched off.
● Only leave the machine once you are sure that the line you have
touched or damaged has been deenergised.
Electricity generator works are always equipped with automatic start‐

up systems. If a circuit breaker trips, the short-circuited line will be
switched back on again after a brief interval. Brief intervals where the
voltage is absent create a false sense of safety.
You must not move or rescue injured persons until a representative of

the power station has notified you that the line has been switched off.
A radio remote control system only protects the machine operator if

he is standing outside the discharge voltage pattern.

Safety regulations
2.9.6 Earthing in the event of electrostatic charging
Working in the vicinity of transmitters (radio transmitter, etc.) can re‐

sult in faults in the radio remote control system and dangerous electri‐
cal charges in the machine. Persons who bridge the charged parts to
the earth suffer life-threatening electrification on contact.
Machines in use in the vicinity of transmitters must be earthed. This

earthing may only be carried out by trained personnel.
Even with an earthed machine, the safe clearances to high-voltage

lines (Clearances P. 2 — 22) and the instructions relating to storms
and bad weather (Procedure in storms P. 2 — 36) must be complied
with.
If you have any further questions about earthing the machine, please
contact site management or the operator of the machine.
2.9.7 Earthing on construction sites with special installations
When carrying out work in the area of special installations (particular‐

ly overhead lines for railways or substations), it may be the case that
the machine needs to be earthed upon request and in consultation
with the operator of the special installation. This earthing must only be
carried out by qualified personnel.
Even with an earthed machine, the safe clearances to high-voltage

lines (Clearances P. 2 — 22) and the instructions relating to storms
and bad weather (Procedure in storms P. 2 — 36) must be complied
with.
2.10 Stationary machines
2.10.1 Setup site
Stationary machines are generally used on a construction site for a

lengthy period. For this reason, site management should prepare the
setup site carefully. Site management must deliver the necessary
documents in good time in order to be able to prepare the founda‐
tions, base plates or similar on time.
When selecting the setup site, remember that the machine must be
dismantled and transported away again at the end of its use on site.
The ambient conditions may change as construction work progress‐
es.

Safety regulations
Please also observe the (Setup site P. 2 — 27) section.
2.10.2 Stationary placing booms
Stationary placing booms can be erected on tubular columns, lattice

booms or other base structures. The base/structural elements to
which the base structure is fixed must be able to withstand the forces
and moments transferred via the base structure, as specified in the
manufacturer’s information. The base frame of the base structure
must be fastened in place so that it is level on the base/structural ele‐
ments in every direction. Check the documentation provided by the
manufacturer in this regard and the corresponding notes in the oper‐
ating instructions.
2.10.3 Lifting machines and components
Machines which are transported to the setup site in individual parts or

not under their own power must only be lifted with suitable lifting
equipment in accordance with the specifications in the Operating In‐
structions. The lifting gear on the machine must be capable of accept‐
ing the lifting equipment and lifting the load. Noone should stand un‐
der suspended loads. Before work is started, a subject expert must
check that the assembled machine is working properly.
2.10.4 Loading and transporting
Only use suitable means to load and transport stationary machines.

Ensure that noone can be injured by the machine tipping over or slip‐
ping.
The machine/components must be properly secured during transport.

Many lifting points fitted to the machine are provided for assembly
purposes only. They are not suitable for lifting the complete machine.
The lifting points for lifting the entire machine are specially marked.

Safety regulations
The transport vehicle and machine must be marked to conform with

the road traffic regulations in the country concerned if they are to use
the public highway.
Please also observe the (Driving P. 2 — 31) section.
2.11 Mobile machines
2.11.1 Setup site
Site management must prepare and assign the set-up site. It is the
machine operator who takes responsibility for setting up the machine
safely. The machine operator must inspect the setup site proposed by
site management and must refuse to set the machine up at the site of
operations if there are any doubts regarding safety.
As machine operator, you must familiarise yourself with the working

area and surroundings before work is begun. The working area and
surroundings include, in particular, obstacles in the work and travel‐
ling areas, the load-bearing capacity of the supporting ground and
any barriers separating the construction site from public roads.
The setup site must have sufficient lighting to ensure safe operation
of the machine. Ensure that the setup site is adequately lit.
Do not set up the machine in areas where equipment may fall down.
Incidents of overlapping with the working areas of other machines

(particularly cranes, other placing booms, etc.) should be avoided as
far as possible. If this is not possible, special care and attention is re‐
quired when setting up and operating machinery. If necessary, you
must use a signaller.
You must also check the approach route to the site where the ma‐
chine will be set up. If you are unsure whether the approach route is
suitable, prepare the route before work is started. It is especially nec‐
essary to walk the approach route once in darkness and at dusk or
dawn. You should repeat this exercise again before leaving the con‐
struction site.
Always ask for a signaller if you need to reverse. If necessary, have

the approach route closed off or secured by signallers. Have any ma‐
terials or equipment that hinder your approach removed.

Safety regulations
2.11.2 Supporting ground
Find out the load-bearing capacity of the supporting ground. The site
management will be able to state the permitted ground pressure. If
the load-bearing capacity is unknown, assume the that worst case
scenario applies.
The supporting ground must be level and even. If necessary, set up a

level surface on top of the uneven ground. There must be no voids or
other ground irregularities under the support feet. Asphalt, concrete
slabs, etc. may have been washed out underneath. Never set the ma‐
chine up on backfilled ground, obvious or known voids or uneven
ground.
The support area must be enlarged as required. Support plates and

timber blocks may be used to increase the support area. The sup‐
ports must be undamaged and free from ice, oil, grease, etc. The
support blocks and timber blocks must be laid under the support
plates such that the load is distributed uniformly and the support leg
cannot slip off the side of the support.
Check the stability of the machine regularly during operation. Interrupt

the pumping operation if the machine becomes unstable.
Factors which reduce stability include, for instance:

● Modifications to the ground conditions, particularly caused by rain
water or the thawing of frozen ground
● The support sinking on one side
● Fluid losses through leaks in the support hydraulics

Safety regulations
2.11.3 Corner bearing loads
The corner bearing load is stated on each support leg. This value
must always be legible.
The load supported by each support leg is conically diffused in the

ground at an angle of 45 °. Safe clearance to the pits and slopes must
be maintained, and such clearance must be determined in accord‐
ance with the nature of the ground. The safe clearance is measured
from the foot of the pit.
The following guide values apply:

● On undisturbed, compacted ground, the safe clearance corre‐
sponds to the pit depth, but must be at least 2 m.
● On loose or backfilled ground, the safe clearance corresponds to
double the pit depth, but must be at least 2 m.
If the ground conditions are unclear, you must contact the site man‐
agement and enquire about the required minimum clearance.
2.11.4 Supports
The placing boom must not be raised until the machine has been sup‐
ported in accordance with the Operating Instructions. There is other‐
wise a risk of the machine toppling over.
Swing out and telescope the support legs to their end positions in se‐
quence. Intermediate positions are prohibited to guarantee stability.
Exceptions are machines which have been equipped by the manufac‐

Safety regulations
turer with a device which allows secure erection with a reduction in

support. Check the corresponding notes in this regard in the operat‐
ing instructions.
Do not carry out more than one movement at a time. If a movement is

stopped, the entire volume of fluid is available for the remaining
movements, and can increase their speeds. Depending on the de‐
sign, it may be the case that carrying out several movements at once
(as opposed to carrying out a single movement at maximum speed at
any one time) does not bring any advantage in terms of time. Carry‐
ing out several movements at once requires an increased level of at‐
tentiveness.
Lock all supports mechanically, if this is provided for in the design.

Close all shut-off valves in the support hydraulics. Leaks can cause
the supports to sink on one side.
The machine must be made level in all directions. Provided the manu‐
facturer does not state otherwise, the maximum permissible deviation
from the horizontal is 3 °. Greater deviations from the horizontal over‐
load the slewing gear for the placing boom as well as its overall sup‐
port structure, jeopardising the stability of the machine.
Check stability regularly during operation. The elastic distortions to

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

Safety regulations
2.11.5 Driving
When preparing the machine for driving, you must perform the follow‐
ing tasks in particular:
● The placing boom must be folded in fully and positioned on the
placing boom support provided.
● The support legs and support feet must be fully retracted and se‐
cured.
● Raised or locked axles must be lowered and released.
● Accessories and moving parts belonging to the machine must be
safely stowed/secured.
● The maximum permissible gross weight must not be exceeded.
While the vehicle is being driven, the delivery line, pump and hopper
must be empty. If there is concrete residue in the hopper, there is a
risk of injury from the concrete residue, which may be thrown out
while the vehicle is in motion. This also affects the centre of gravity of
the machine. Observe the road traffic regulations and specifications
of the machine manufacturer.
Maintain a distance of at least 1 m to the secured edges of the pit and

a distance of at least 2 m to slopes.
Always make sure that there is sufficient clearance when driving un‐
der underpasses, over bridges and through tunnels or when passing
under overhead cables. The same minimum clearances apply when
driving under high-voltage lines as when working with the placing
boom. Be aware of the height of the truck. Only drive over arches,
bridges or other supporting structures if their load-bearing capacity is
sufficient.

Safety regulations
Do not drive across uphill or downhill gradients. Be aware of the ele‐

vated position of the truck's centre of gravity when travelling on a
slope and on ascending or descending routes. Always adapt your
travelling speed to the prevailing conditions on sloping terrain.
Observe national road traffic regulations. If necessary, clean the

tyres, lights and number plate. Before travelling with the machine,
check that the braking, steering, signalling and lighting systems are
fully functional.
Persons accompanying the driver must be seated on the passenger

seats provided for this purpose.
For truck mixer concrete pumps, only turn the mixer drum at the maxi‐
mum specified speed of rotation whilst the truck is in motion. The
truck is at risk of toppling over, particularly when travelling round cor‐
ners.
2.11.6 Towing
The machine must only be towed, loaded and transported in accord‐

ance with the Operating Instructions. Only use existing towing hitches
for towing and observe the truck manufacturer's regulations.
You must comply with the prescribed driving position, permitted

speed and itinerary when towing.
2.11.7 Loading
Many lifting points fitted to the machine are provided for assembly
purposes only. They are not suitable for lifting the complete machine.
The lifting points for lifting the entire machine are specially marked.

Safety regulations
Use only appropriate means of transport and lifting equipment of ade‐

quate load-bearing capacity. Lifting equipment, lifting tackle, support
trestles and other auxiliary equipment must be reliable and safe in op‐
eration.
Only load the machine on stable loading ramps of adequate load-

bearing capacity. Ensure that noone is at risk from the machine tip‐
ping over or slipping.
Secure the machine on the transport vehicle to prevent it rolling away,

slipping and toppling over.
2.12 Placing booms
2.12.1 Unfold placing boom
Only raise a mobile placing boom from the driving position once the
machine has been supported in accordance with the Operating In‐
structions. Stationary placing booms may only be raised after the
proper set-up has been checked by a subject expert.
Only raise the placing boom in the sequence described in the Operat‐
ing Instructions. The correct sequence depends on the “Folding sys‐
tem” (roll-and-fold system, Z fold system, etc.).
Do not carry out more than one movement at a time. If a movement is

stopped, the entire volume of fluid is available for the remaining
movements, and can increase their speeds. Depending on the de‐
sign, it may be the case that carrying out several movements at once
(as opposed to carrying out a single movement at maximum speed at
any one time) does not bring any advantage in terms of time. Carry‐
ing out several movements at once requires an increased level of at‐
tentiveness.
The range of a radio remote control is long enough for the machine to
receive control commands (e.g. from a great distance, from inside en‐
closed spaces) even without visual contact. If there is no visual con‐

Safety regulations
tact, for example, because you are changing workplace, you must
switch off the remote control. If there is no visual contact, for exam‐
ple, because the construction site is unclear, signallers MUST be
used, and must remain in contact with the machine operator using
suitable means, and have visual contact with the site of concrete
placement, work areas and danger zones, and the machine.
Always ask the site management to provide you with an assistant to

act as a signaller. Agree clear hand signals or other signals with the
signaller so that you can communicate with each other. You should
position the signaller such that he can always observe the whole of
the placing boom. Your primary duty as the machine operator is to
observe the site of concrete placement.
Only slew the placing boom over persons when the delivery line and
end hose are empty. There is a risk of concrete falling out of the end
hose.
Press the EMERGENCY STOP BUTTON immediately if the placing

boom moves unexpectedly. If this should occur, you must cease
working and have the cause of the fault rectified by your qualified per‐
sonnel or our After Sales Service personnel.
Placing booms with placing boom hinges which allow considerable

flex angles have a very large potential working area. This high ma‐
noeuvrability means different placing booms can also be moved into
dangerous positions. Prohibited areas can be found in the Operating
Instructions.
There is a risk that you will damage the truck, truck superstructure or
obstacles on the construction site with the placing boom. Under cer‐
tain circumstances it is even possible to overload or cause damage to
the placing boom. Uncontrolled movements may result from the sud‐
den, violent release of the placing boom after collisions. This may al‐
so result in (possibly fatal) personal injury.

Safety regulations
The manufacturer has indicated such impermissible working areas by

the use of warning signs and information plates on the machine and
appropriate notes in the Operating Instructions.
2.12.2 End hose
The end hose must hang freely each time you start pumping, when
you start pumping again after blockages, and during cleaning proce‐
dures. Noone should stand within the danger zone of the end hose.
The diameter of the danger zone is twice the end hose length. Do not
guide the end hose when pumping is started. There is a risk of acci‐
dent from the end hose swinging out or stones being ejected.
When using a longer end hose, the diameter of the danger zone also
increases. (Extending the placing boom and end hose P. 2 — 13)
End hoses with a length of more than 4 m must not be guided by

hand.
The end hose must not impede the movement of the placing boom; in
particular, the end hose must not catch on the reinforcement or form‐
work. There is a risk of death if the machine topples over or the end
hose shoots out on further movement of the placing boom.
Never bend the end hose over. Never attempt to straighten a bent
end hose by increasing the pressure. The end hose must not be sub‐
merged below the surface of the concrete being delivered, otherwise
the concrete may spray upwards.
The concrete may also spray from the end hose due to the presence
of air in the delivery line. To prevent this from occurring, the hopper
must be filled with concrete at least as far as the agitator shaft so that
no air can be sucked in.
The end hose must be secured against falling.

Safety regulations
2.12.3 Guiding the end hose ergonomically
The hoseman must guide the end hose in such a way that prevents
excess spraying of concrete, and so that concrete is directed precise‐
ly into the site of concrete placement.
Control the placing boom so that the hoseman can guide the end
hose without power consumption. The hoseman must not carry the
end hose by hand, because the weight of it may cause permanent
personal injury.
2.12.4 Connecting drills
If a drill is connected to the delivery line for the placing boom, it must
not place any further strain on the placing boom. The placing boom
must be connected to the drill in such a way that the placing boom
does not require adjustment. There should be 1-2 delivery hoses be‐
tween the placing boom and the drill; these must be secured so that
they cannot move in an uncontrolled manner. If the drill is moved on
the construction site, the placing boom must not be connected.
2.12.5 Procedure in storms
Return the placing boom to the driving position or rest position in the
event of storms or bad weather.
● Placing booms with a vertical reach of 42 m or more must only be
operated in winds of up to wind force 7 (wind speed 51 km/h).
● Placing booms with a vertical reach of less than 42 m may only be
operated in winds of up to wind force 8 (wind speed 74 km/h).
The definitive wind speed is measured at the height of the boom tip.
Wind speeds in accordance with the Beaufort scale are average wind
speeds measured over a period of 10 minutes. Higher speed gusts of
wind may occur briefly during the measuring period.
Higher wind speeds jeopardise the stability and safety of structural el‐
ements. There is a risk of lightning strike in a thunderstorm.
Lightning strikes pose a risk of death. The machine and the surround‐
ing area will be charged with electricity. Earthing the machine does
not reduce this risk. For this reason, you should fold in the placing
boom if there is a risk of lightning strike.

Safety regulations
Tower cranes on construction sites generally have wind speed meas‐

uring equipment, enabling you to find out 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 the trees
and there is perceptible resistance when walking against the wind.
● In winds of force 8 and greater, small branches break from trees
and walking outside is significantly impeded.
2.12.6 Concreting in cold weather
Placing booms must not be used at temperatures of below minus

15 °C (+5 °F) except with the express approval of the manufacturer.
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 realis‐

tic 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.
2.13 Delivery line systems
2.13.1 Suitable delivery lines
Use only delivery lines, end hoses, couplings, etc. which are in per‐
fect condition and suitable for the delivery job and have been ap‐
proved by the machine manufacturer. Delivery lines are subject to
wear which varies according to the delivery pressure, concrete com‐
position, the material from which the delivery line is made, etc.
If you are not responsible for the separate delivery lines, the permissi‐
ble operating pressures of these should be confirmed by the operat‐
ing company.

Safety regulations
2.13.2 Securing delivery lines
Delivery lines, delivery hoses, end hoses and couplings must be se‐
curely fastened and secured to prevent spontaneous opening.
2.13.3 Leak tightness and blockages
Regularly force water through the delivery line under operating pres‐
sure to check that the system is watertight.
A properly cleaned delivery line is the best insurance against the for‐
mation of blockages. Blockages increase the risk of accidents. Never
attempt to push through a blockage (e.g. by increasing the delivery
pressure, using compressed air, etc.). There is a risk of death from
the delivery line bursting or from concrete being ejected from the end
of the delivery line.
Prevent blockages by adjusting the operating conditions. Remove

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

Safety regulations
2.13.4 Opening delivery lines
Delivery lines must not be opened or tapped off while they are pres‐
surised. Concrete exiting under pressure can cause injury. The con‐
crete column must be depressurised by reverse pumping before the
delivery line is opened. Never bend over the coupling when you are
working.
2.13.5 Clearance to delivery lines
Noone should remain in the vicinity of separate delivery lines during

pumping operations. Cordon off the danger zone. If it is not possible
to place a large enough cordon around the danger zone, the delivery
line must be covered by suitable means.
2.13.6 Securing the delivery lines
Delivery lines, in particular riser lines which are not laid along placing
booms, must be securely fastened in order to transfer the forces gen‐
erated in them into the structure or other structural members. The
lines must be laid so as to avoid kinks, sharp bends, stresses and
damage during pumping operations.
2.13.7 Continuation delivery lines
Continuation delivery lines not described in the Operating Instructions

must not put an additional strain on the placing boom.
While you connect, use and disconnect a continuation delivery line,

you must switch off the placing boom control system to prevent unin‐
tended movements of the placing boom. There is a risk of accident
posed by jerky movements of the boom tip.

Safety regulations
2.13.8 Devices for shutting off, diverting and cleaning
During operation, there is a risk of being crushed and of injury by

shearing. Hydraulically driven devices are generally supplied with
power by the hydraulic system of a machine. For this reason, there
must always be a line of sight between the devices and the machine
fitted with the control unit. Observe the safety regulations for the ma‐
chine and the device when connecting and operating a device. Before
operating devices, ensure that no persons are present in the danger
zone.
Use only devices that are suitable and in perfect working order to shut
off, divert and clean the delivery line. Defective and unsuitable devi‐
ces can lead to damage to the entire delivery system and injure peo‐
ple in the vicinity if they fail.
2.14 Pumping operations
2.14.1 Place of work
The machine operator's place of work is with the remote control when
the pump is in operation. If you operate the machine using the remote
control, all operating and control devices on the machine must be
closed to prevent unauthorised access.
In the case of stationary placing booms, platforms or similar equip‐

ment are only provided for assembly and maintenance work. Use of
these platforms as a place of work during operation is prohibited.
It is forbidden to climb onto the machine during operation. In the case

of stationary placing booms, it is forbidden to climb ladders during op‐
eration.
2.14.2 Safety
Before switching on or restarting the machine or individual machine

functions, you must ensure that doing so will not endanger anyone's
safety.
Refrain from any procedures that may impair the stability of the ma‐
chine or are prejudicial to safety in any other way.

Safety regulations
2.14.3 Remote control
You must always carry the remote control on your person when the
machine is ready for operation. Only in this way can it be guaranteed
that you can press the EMERGENCY STOP BUTTON in the event of an
emergency situation. The EMERGENCY STOP BUTTON may only be
unlocked once the cause/emergency has been remedied.
As a general rule, you must carry the remote control so that no con‐
trol elements are activated unintentionally. If your attention is drawn
away from the machine (particularly when changing place of work),
you must switch off the remote control.
During breaks in pumping, interruptions, maintenance work, or before

you leave the machine, you must secure it to prevent unintended
movements and unauthorised use. Switch off the remote control and
lock it away.
2.14.4 Moving machine components and hot surfaces
Keep all access covers, maintenance flaps, guards, etc. closed and
locked during operation. This also applies in particular to the grille,
water box cover and covers over cylinders. There is otherwise a risk
of injury from moving machine components and a risk of burning on
hot surfaces. In particular, there is a risk of burning from the engine,
attached parts and the exhaust.
Never start work unless the grille is closed and bolted down or other‐
wise secured.
Do not touch moving parts of the machine, whether the machine is

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

Safety regulations
Do not insert any objects (shovel handle, trowel, etc.) into moving ma‐
chine components. Such objects could become trapped and dragged
into the machine. They might then hit you or be torn from your hands
and cause you injury.
2.14.5 Constant observation of the machine
You should be constantly observing the machine for any damage or

faults while it is in use. In the event of faults or malfunctions that im‐
pair safety at work, shut the machine down immediately and secure it.
Have the faults rectified immediately. If it is not possible to rectify
faults which jeopardise the safe operation of the machine, you must
suspend operations until the defects are rectified.
2.14.6 Truck mixer
As the machine operator, it is your role to instruct the truck mixer driv‐
ers who deliver the concrete to you, so that they are able to operate
the operating elements on the concrete pump provided for their use.
Only allow the truck mixer drivers to work alone once you are certain
that they have understood your instructions.
Make sure that no-one stands between the approaching truck mixer
and the machine. There is a risk of crushing between the truck mixer
and the machine.
2.15 Cleaning
2.15.1 General
You must drain the delivery line, pump and hopper completely. Con‐
crete residue in the hopper, in particular, may be thrown out whilst the
truck is moving.
The machine must not be driven with the placing boom unfolded or
the support legs extended, even over short distances. This rule also
applies when you have to drive the machine to a different site for
cleaning. The placing boom and support legs must be fully retracted
and secured.

Safety regulations
The preferred methods for cleaning the delivery line are reverse
pumping or forced cleaning with water. The agitator must be switched
on during reverse pumping. Otherwise, the concrete flowing back into
the hopper can bend the agitator shaft. Use a catch basket, pipe
cleaning head and wash-out ball for forced cleaning to prevent any
water from flowing into the formwork.
Never spray remote controls or control cabinets with barrier agents

(mould oil or similar) to protect them against contamination. This cau‐
ses significant corrosion damage to the electrical system.
There is a risk of injury at all points on the machine from slipping, trip‐
ping, bumping into things, etc. Use the handles and steps to climb in‐
to and out of the machine. It is forbidden to stand on the grille. Do not
jump from the machine.
Do not reach into the hopper or any other moving machine compo‐
nents. This rule must also be followed when you are opening the out‐
let on the bottom of the hopper. Do not remove the grille.
Only point the water jet into the hopper or other moving machine
components. Do not insert the hose. It could become entangled with
moving machine components.
2.15.2 Cleaning agents
Take care when using aggressive cleaning agents. Aggressive clean‐

ing agents may attack materials (e.g. rubber) and painted surfaces.
You can use commercially available paint cleaning and care agents,
as long as these have a pH value of between 4 and 9. Ask the manu‐
facturer of the cleaning agent to confirm its suitability. Observe the

Safety regulations
manufacturer's instructions regarding use and safe handling. Wear

protective clothing. Always rinse off cleaning agent thoroughly with
clean water; do not allow puddles to form.
Do not use sea water or other water containing salt for cleaning pur‐
poses.
Do not use any highly flammable agent for cleaning; there is a risk of
fire.
2.15.3 Cleaning with compressed air
When the delivery line is being cleaned with compressed air, there is
an increased risk of accidents caused by compressed air escaping
explosively, spurting concrete, and delivery or end hoses moving un‐
controllably if they have not been removed.
Compressed air should only be used for cleaning purposes under the
supervision of a subject expert. All persons participating in the clean‐
ing procedure must be instructed in the safety regulations.
The manufacturer accepts no liability for damage caused by incorrect‐

ly performed compressed air cleaning. You must observe the follow‐
ing rules without fail when you use compressed air to clean out the
delivery line:
● Individual pipes and short pipe runs up to 10 m in length must not
be blown through with compressed air. There is a risk of accident
from rebound.
● Only blow out delivery lines that have the same nominal diameter
throughout their length. Reducer pipes must be drained and flush‐
ed out by hand.
● No delivery or end hoses may be fitted at the end of the delivery
line.

Safety regulations
● A catch basket must be fastened at the end of the delivery line and
a wash-out adaptor must be fitted on the head of the delivery line.
The catch basket and washout adaptor must fit the delivery line
system.
● The concrete must be able to flow freely from the end of the deliv‐
ery line.
● There must be no persons present within the danger zone around
the delivery line, at the end of the delivery line and, in particular, in
front of the opening in the catch basket.
● Care must be taken to ensure that any concrete that might be ex‐
pelled from the catch basket cannot injure anybody or cause any
damage.
● The wash-out adaptor must be fitted with a separate, large dump
cock and a pressure gauge.
● The pressure gauge must be kept under constant observation dur‐
ing the cleaning process. The pressure in the delivery line must be
rapidly dumped via the dump cock in the event of a sudden drop in
pressure (concrete column exiting from the end of the line) or in‐
crease in pressure (risk of blockage).
● The sponge ball or the plug used to push the concrete out must be
sufficiently dense that the air does not pass through it into the con‐
crete. In addition, the delivery line must be sealed to the rear when
the sponge ball or plug is caught in the catch basket.
● Only work on the delivery line (particularly when opening the deliv‐
ery line) if it has been depressurised. Make sure that the com‐
pressed air has been dumped completely.
● The dump cock must be opened in such a way that no-one can be
injured by concrete residue that might be expelled from the dump
cock.
● Separate delivery lines that are cleaned with compressed air must
be securely fastened so that they cannot move uncontrollably.
● If continuing distribution systems (e.g. rotary distributors), gate
valves or other delivery line elements are connected to the delivery
line, they must be secured in such a way that they cannot move
uncontrollably.
● Ensure that any elbows on the end of the delivery line are removed
in the case of rotary distributors.

Safety regulations
2.15.4 Protection against water
Water spraying on the machine from random directions has no dam‐

aging effect. The electrical system is protected against spray water,
but is not waterproof.
You must close/seal all openings into which water/steam/cleaning

agent must not penetrate for safety or functional reasons before
cleaning the machine with water or a steam jet (high-pressure clean‐
er) or other cleaning agents. Electric motors and control cabinets are
particularly at risk.
2.15.5 Post-cleaning procedure
After the machine is cleaned, the covers/tapes must be completely re‐

moved and the machine must be checked to ensure that it is ready for
operation (Before working with the machine P. 2 — 21).
Look out for leaks, loose connections, chafe marks and damage dur‐
ing the cleaning procedure. Any identified defects must be rectified
immediately. The machine must be greased after it has been cleaned
using a highpressure cleaner.

3 General technical description
This chapter describes the structure and method of operation of the
components on this machine. Please note that possible (optional) ad‐
ditional equipment is also described. Refer to the machine card to
check whether you have the particular additional equipment or not.

General technical description
3.1 Overviews
Item Designation
1 Pressure gauge for hydraulic fluid filter wear
2 Pressure gauge for hydraulic fluid pressure
3 Control cabinet
(Control cabinet P. 3 — 25)
Core pump operating panel
(Core pump operating panel P. 3 — 26)
5 Cable remote control
(Cable remote control P. 3 — 45)
6 Hydraulic fluid radiator
7 Accessory assembly frame

(e.g. compressor)
8 Machine rating plate

(Machine rating plate P. 3 — 19)
9 Water box
10 Bracket for cable remote control
11 Documentation accompanying the machine

Item Designation
1 Coolant filler opening
(with vent valve)
2 Coolant fill level indicator
3 Fuse box
4 Battery
Item Designation
1 Fluid drain cock
2 Hydraulic fluid filler opening
3 Fill level indicator for hydraulic fluid reservoir
4 Water pump/agitator lever

Item Designation
5 Fuel filler opening
6 Centralised lubrication system

(Centralised lubrication system P. 3 — 60)
3.2 Safety equipment

This chapter contains the following information about the safety
equipment:
● Overview
● Intervals for inspections
● Description of individual assemblies
3.2.1 Overview
Item Designation
1 Grille
2 Spray guard
3 Protective grille
(on the hydraulic fluid radiator)
4 Heat protection plate
5 Protective grille
(on the motor oil radiator)
6 Stop pin with spring pin

(on all support feet)

Item Designation
7 Protective grille
(on the water box)
8 Agitator safety cutout

(Agitator safety cutout P. 3 — 11)
9 Spray guard
The positions of the EMERGENCY STOP buttons are listen in the

following chapter:
(EMERGENCY STOP function P. 3 — 8)
3.2.2 Safety components
WARNING
Risk of death due to malfunction
▶ Safety components should only ever be repaired, maintained or
replaced by qualified personnel with the necessary authoriza‐
tion.
The following components are safety components:

● Load-holding valves (isolators)
● Pressure limiting valves
3.2.3 Safety-related parts (SRPs)
WARNING
Risk of death
Incorrect assembly of safety-related parts can result in malfunc‐
tions.
▶ Safety-related parts (SRP) should only ever be repaired, main‐
tained or replaced by qualified personnel with the necessary au‐
thorization.
Safetyrelated parts (SRP) are components that ensure the safety of

the machine functions. They are specially marked on spare parts
sheets. When a spare part that can be used as an SRP is ordered, it
is delivered in separate, clearly labelled packaging.

Read the “EB00-5-xxxxx-xxxx” sheet to ensure that you are aware of

the SRPs fitted on the machine.
Figure 3: SRP marking
Item Designation
Left Spare parts sheet
Right Spare part packaging
1 2 3 4 5
BP15_013_1412DE 2
Figure 4: Extract from an example spare parts sheet
Item Designation
1 Asterisk “*” – item cannot be ordered
2 Exclamation mark “!” - Safety-related part (SRP)
3 SRP service life in years

10 = 10 years

Item Designation
4 Hourglass – SRP service life
5 Example spare parts sheet “EB00-5-xxxxx-xxxx”
Putzmeister specifies a service life (3) for every safety-related part

(SRP). The SRPs must be replaced once this service life has
elapsed.
3.2.4 Plates
Plates on the machine warn operators of dangers that cannot be pre‐

vented by means of the design.
You will find the locations of the plates on the machine circuit dia‐
grams, which indicate which plate should be affixed where.
3.2.4.1 Check function
Monthly
1. Check whether the plates that are required in the specified loca‐
tions of plates have been affixed on the machine.
2. Check the plates for damage.
3. Replace any missing, damaged or illegible plates with new ones.
3.2.5 EMERGENCY STOP function
Safety function: Emergency shutdown function
DIN EN ISO 13849-1:2015 Category 1 PL c
3.2.5.1 Function
As soon as an EMERGENCY STOP BUTTON is pressed, all dangerous

machine movements stop. The following actions are triggered:

Area Action
Core ● The agitator stops
pump ● The transfer tube stops
● The delivery pistons stop
● The accumulator dump valve is opened and the ac‐
cumulator is emptied
● The variable main pumps swing into the idling posi‐
tion
Drive ● Motor speed drops to idle
● It is no longer possible to set the motor speed elec‐
trically
Table 1: Actions triggered by the EMERGENCY STOP function
3.2.5.2 Positions of the EMERGENCY STOP buttons
● Next to the control cabinet

● On the left-hand side opposite the control cabinet
● Cable remote control
3.2.5.3 Deactivating the EMERGENCY STOP
1. Make sure that possible causes for an EMERGENCY STOP are

rectified.
2. Turn the pressed EMERGENCY STOP BUTTON.

⇒ You have unlocked the EMERGENCY STOP button.
3. Press the “Deactivate EMERGENCY STOP” BUTTON.
➙ The EMERGENCY STOP is deactivated.

3.2.5.4 Checking the EMERGENCY STOP function
Each time before the machine is used
WARNING
Risk of death due to a defective EMERGENCY STOP button
The machine cannot be switched off quickly enough in the event of
impending danger if the EMERGENCY STOP button is defective.
This means that the machine is no longer safe to use.
▶ Check that the EMERGENCY STOP button is working properly
before starting work each time.
It is only possible to intervene quickly in the event of danger if all the

EMERGENCY STOP buttons are working properly.
1. Start the machine up.

⇒ (Starting up P. 5 — 3)
2. Switch on the core pump.
3. Switch the agitator on.
Figure 5: EMERGENCY STOP button
Item Designation
1 Press: Locks EMERGENCY STOP button
2 Turn: Unlocks EMERGENCY STOP button
4. Press one of the EMERGENCY STOP BUTTONS.

⇒ All safety actions are carried out immediately.

Area Action
tion
trically
5. Check all EMERGENCY STOP buttons on the machine.

6. Check all EMERGENCY STOP buttons on the cable remote con‐
trols.
3.2.6 Agitator safety cutout
Safety function: Safety-related stop function, initiated by a protective

device
DIN EN ISO 13849-1:2015 Category 1 PL c

3.2.6.1 Structure
The agitator safety cutout is located on the hopper. The installation lo‐
cation on the hopper varies.
Figure 6: Function check of the agitator safety cutout (RSA)
Item Designation
1 Reading head (on the hopper – example illustration)
2 Green and red LEDs
3 Transponder (on the grille)
3.2.6.2 Function
The agitator safety cutout stops the movement of components in the

hopper when the hopper monitor detects a possible interference with
the hopper.
The agitator safety cutout is activated by the following actions:

● Opening the grille
● Activating the EMERGENCY STOP
● Switching on the machine
(not switching on the motor)
As soon as you open the grille, the radio link between the transpond‐
er and the reading head is broken.

The LEDs on the evaluation device indicate the following:

● Green LED:
● Flashes for 8 seconds during the initialisation process
● Lights up during normal operation when the grille is closed
● Flashes when the grille is open
● Red LED:
● Lights up when there is a fault with the evaluation device
The agitator safety cutout is triggered if an evaluation device is de‐

fective.
Safety ac‐ ● The accumulator dump valve is opened and the ac‐
tions cumulator is emptied.
● The agitator stops.
● The transfer tube stops.
Process- ● The delivery pistons move to the end position and
related ac‐ then stop.
tions
Table 3: Actions of the agitator safety cutout
The core pump is secured against unexpected restarts. When starting

up the machine and when the agitator safety cutout has been trig‐
gered, it must be deactivated before the core pump can be switched
on.
3.2.6.3 Deactivating the agitator safety cutout
WARNING
The agitator can start up unexpectedly
1. Do not tamper with the agitator safety cutout.
2. The machine must only be operated if the agitator safety cutout
is intact.

up the machine and when the agitator safety cutout has been activa‐
ted, you must deactivate the agitator safety cutout for the core pump
to work.

1. Make sure that there is only conveyed material in the hopper.

2. Close the grille.
You can deactivate the agitator safety cutout on the core pump oper‐
ating panel.
3. Press the “Deactivate agitator safety cutout” BUTTON.

➙ The stroke correction is started up.
➙ You have deactivated the agitator safety cutout.
You can switch on the core pump.
3.2.6.4 Checking the agitator safety cutout
WARNING
is intact.

Figure 7: Agitator safety cutout function check
2. Open the grille.
tions
⇒ A message is shown on the display:
The safety actions are not carried out?

1. Switch off the core pump.
2. Switch off the machine.
3. Have the agitator safety cutout repaired.

4. Deactivate the agitator safety cutout.
⇒ (Deactivating the agitator safety cutout P. 3 — 13)

➙ You have checked the agitator safety cutout.
3.2.7 Grille
The grille is a passive safety function (separating protective device).

The bar spacing is selected in such a way that it allows concrete with
defined particle sizes to flow into the hopper. The bars are subject to
natural wear.
3.2.7.1 Check wear
Monthly
WARNING
Moving parts in the hopper
1. Do not reach into the hopper.

2. Do not insert any objects through the grille.
3. Never operate the concrete pump without the grille in place.
4. Check the wear to the grille at regular intervals.

Figure 8: Bars of the grille
1. Measure the width (W) and height (H) of the bars in an area with
high wear, preferably in the middle of the grille.
2. Measure the width (W) and height (H) of the bars in an area with
the least wear (edge of the grille).
3. Compare the values measured.
4. Replace the grille if the residual material thickness has fallen be‐
low the minimum permitted level.
5. Inspect the grille for any other damage (broken bars, cracked
seams, etc.).
6. Replace the grille if there are any visible breaks or cracks.
If you have replaced the grille:
7. Have the agitator safety cutout readjusted by authorised qualified
personnel.
3.3 General conditions for using the machine

General conditions are control values, which are partly given as phys‐
ical conditions and which set limits for using the machine.
3.3.1 Service life
If operated, maintained and checked correctly, and if original or equiv‐

alent spare parts and accessory components are used, the service
life is 15 years.

Designation Value
Output per year 20,000 [m3]/year
Operating hours 400 [h]/year
Uses per day 1
Uses per year 250
3.3.2 Site of use
The machine is designed for industrial use on outdoor construction

sites, or indoors with adequate ventilation. It must not be used in
areas where there is a potentially explosive atmosphere.
3.3.3 Operating altitude
Putzmeister must be contacted if the machine is to be used at an alti‐

tude greater than that given here. The standard reference level is the
European standard elevation zero (NHN).
Designation Value
Maximum operating altitude 2500 m
3.3.4 Operating temperature
Contact Putzmeister if you wish to operate the machine outside the

permitted operating temperature.
Designation Value
Stationary concrete pump with diesel -8 – +45 °C
engine*
Stationary concrete pump with diesel -8 – +45 °C

engine*
* Limited due to the diesel engine without preheating device. When

using below -8 °C, a preheating device must be installed.

3.4 Machine rating plate
Figure 9: Rating plate
Machine data
Item Designation
1 Manufacturer's address
2 Machine model
3 Designation of the machine
4 Machine number
5 Chassis number
6 not present
7 Year of manufacture
8 not present

Item Designation
Operating data
Item Designation
9 Maximum fluid pressure in the hydraulic system
10 Maximum delivery pressure
11 Delivery line cross section:

Outside diameter x wall thickness
12 not present
13 Gross weight
14 not present
If specific details do not apply to a machine, the relevant fields are

blank.
3.5 Sound pressure level/sound power level
CAUTION
Damage to health caused by noise emissions
Discomfort, stress, fatigue, hearing impairment or numbness may
be caused by excessive machine, engine and pump noises or by
the noise from the S transfer tubes that are switching over.
1. Wear suitable ear defenders.
2. During operation, ensure that all of the noise protection covers
have been attached to the machine.
3.5.1 Sound pressure level
The workplace is on the remote control. The machine has a sound

pressure level of 85 dB(A) within a radius of 16 m. Hearing protectors
are required.
3.6 Electromagnetic compatibility (EMC)

This machine fulfils the requirements of Directive 2014/30/EU.

Its electromagnetic compatibility has been tested and meets the fol‐
lowing requirements:
● DIN EN ISO 13766-2:2018
Test report number:
P200384
The machine can be used in residential areas without restriction.
3.7 Putzmeister Connected Services

This machine transfers non-personal machine data to Putzmeister in
real time. The machine data is saved and aids Putzmeister in the de‐
velopment of new products.
The operator can object to the transfer of operating data at any time.
For questions, please e-mail:
connectedservices@putzmeister.com
Putzmeister also offers the following services:

● Remote Service
● Machine Cockpit
3.7.1 Remote Service
The After Sales Service personnel and your dealer can identify prob‐
lems more quickly using the “Remote Service” web app.
3.7.2 Machine Cockpit
The operating company can monitor data regarding the machine’s op‐
erating state as well as its location with the “Machine Cockpit” web
app.
3.8 Exhaust after treatment

Exhaust After Treatment (EAT) = exhaust after treatment
The exhaust after treatment is described in detail in the supplied

engine manufacturer’s Operating Instructions.

3.8.1 Function
The engine’s exhaust gas undergoes after treatment in order to com‐

ply with the permitted exhaust gas values.
Observe the applicable national exhaust gas emission regulations to

ensure compliance with exhaust gas emission levels.
The engine and the exhaust after treatment system are coordinated
with each other.
Observe the requirements and recommendations for functional fluids

(lubricating fluid, permitted fuels, coolant and diesel exhaust fluid) in
the supplied engine manufacturer’s documentation.
The components of the exhaust after treatment system and common‐

ly used abbreviations for these are briefly described below.
Term Description
Diesel Exhaust Fluid (DEF) Urea solution which is used and
= diesel exhaust fluid consumed during the exhaust
after treatment (e.g. AdBlue)
Diesel Oxidation Catalyst (DOC) Catalytic converter which burns
= diesel oxidation catalyst off carbon monoxide in exhaust
gas to form carbon dioxide
Diesel Particle Filter (DPF) ● Filter which separates soot
= diesel particle filter from exhaust gas
● Must be cleaned by means of
stationary regeneration
(Regeneration P. 3 — 22)
Selective Catalytic Reduction Continuously reduces nitrogen
(SCR) oxide (NOx) emissions in the
= selective catalytic reduction exhaust gas by adding diesel
exhaust fluid (DEF)
3.8.2 Regeneration
Regeneration is a cleaning process for the diesel particle filter.

Designation Value
Duration Approx. 40 min
Temperature Approx. 580 °C
The diesel particle filter fills up with the filtered out diesel particles
during operation. Diesel particles are burned during normal operation.
Regeneration is required if not all diesel particles are burned during

operation due to external circumstances (e.g. switching the motor on
and off frequently, frequent cold starts).
The exhaust after treatment system will be damaged if you fail to start
regeneration when it is required despite a higher escalation level.
3.8.3 Starting regeneration
If the current motor speed is sufficient for regeneration, the regen‐

eration process will start automatically.
The display on the control cabinet will show messages when regener‐
ation is advisable or required.
(Messages P. 3 — 42)
WARNING
Risk of burning
▶ Stay clear of the exhaust after treatment system – particularly
during and after regeneration.
The motor speed may need to be increased to start regeneration. For

technical reasons, the motor speed can only be increased when the
core pump is switched off.
▶ Switch off the core pump.
⇒ The motor speed increases.
⇒ Regeneration starts.

You can switch on the core pump once regeneration has started.
3.9 Colour definition – LEDs in the button

Each BUTTON on the operating panels of this machine has four integra‐
ted LEDs that indicate the status of a function as follows:
1 2 3 4
Figure 10: Example illustration: Switch support leg monitoring on/off button
Item Designation
1 Red LED
Function locked
A function will be locked in the following example situations:
““Deactivate EMERGENCY STOP”” has not been acknowledged
““Acknowledge agitator safety cutout”” has not been acknowledged
The machine is in remote operating mode
2 Yellow LED
The yellow LED lights up briefly when a function is started.
3 Green LED
The function is active
4 Blue LED
The function is enabled
If no button LED lights up, either the function is not available on

the machine or the LED is defective.

3.10 Control cabinet

You can control the functions of the machine from the control cabinet
and obtain information about the machine’s operating state.
Operating elements
Item Designation
1 Display
(Display P. 3 — 28)
2 Core pump operating panel
3 Keyswitch with the following switch positions:
Machine off
Control system on
Engine on
Connections
Item Designation
4 Diagnostics socket
5 USB charging connection
6 Power supply
7 Motor
8 Core pump
9 Remote control
(radio receiver or cable remote control)
10 Wiring loom for components on the hopper
11 Vibrator

3.11 Core pump operating panel

The core pump operating panel is located at the control cabinet.
LEDs are integrated in each button on the operating panel.

(Colour definition – LEDs in the button P. 3 — 24)
The operating panel is divided into columns of three buttons each.
Button Function
● Deactivating the EMERGENCY STOP
● Horn
(sounds for as long as the button is pressed)
Deactivating the agitator safety cutout
Manually starting the core pump lubrication proce‐

dure
Table 5: Column 1

Button Function
Forward pumping On/Off
Reverse pumping On/Off
Core pump off
Table 6: Column 2
Button Function
Increasing output
Reducing output
Vibrator On/Off
Table 7: Column 3
Button Function
Increase motor speed
Reduce motor speed
ergonic Output-Control On/Off
Table 8: Column 4

Button Function
Agitator On/Off – for forward pumping
Agitator On/Off – for reverse pumping
Loading the last saved core pump parameters
Table 9: Column 5
3.12 Display
The software is shown on the display. You can operate the software
with the display’s operating elements.
Pos. Description Function

1 Display Software display
2 Operate function
Function button
3 ● Return to higher-level menu
esc button
● Cancel input

Pos. Description Function

4 ● Select submenu
Direction key ● Select value
● Change value
5 ● Open selected submenu
ok button
● Confirm input
6 System LED ● When lit: Power supply is switch‐
ed on
● When flashing: System is switch‐
ed on
3.13 Software
The software is operated with the display’s operating elements:
(Display P. 3 — 28)
The software starts with the main menu.
3.13.1 DEF tank
The fill level of the DEF tank is displayed in every menu. The motor
power is reduced when the fill level is low.
DEF tank full
● Red bar: DEF fill volume below

20%
● Flashing symbol: DEF fill volume
below 3%
● Motor power reduced to 50%

3.13.2 Main menu
The software messages are described in the “Messages” chapter.

The machine’s general operating state is shown in the main menu.
The main menu is divided into the following three areas:
Navigation bar
(only in main menu)
Menu content
Function bar
3.13.2.1 Navigation bar
The navigation bar only appears in the main menu.
You can use the navigation bar to navigate to the submenus.
Symbol Menu
User settings
Core pump
Motor

Symbol Menu
Inputs and outputs
Machine information
The symbol of the preselected submenu has a blue frame.
3.13.2.2 Menu content
Item Designation
1 Hydraulic fluid temperature
2 Core pump status
3 Current output
(in m3/h and in %)
4 Display of an EMERGENCY STOP
5 Fuel tank fill level
6 Motor speed of rotation
7 Display of an agitator safety cutout
The core pump status is indicated by the following symbols:

Status dis‐ Description

play
Core pump off
Forward pumping
Reverse pumping
3.13.2.3 Function bar
You can switch functions on and off or switch them over in the func‐
tion bar. The availability of functions depends on the equipment of the
machine and the open menu.
The symbol lights up green if a function is active.

play
Compressor on/off
Fill-level sensor in the hopper on/off

Fill-level sensor off
Fill-level sensor on
Hopper filled
Hopper empty
Core pump stopped automatically
Working light on/off

3.13.3 “User settings” menu
In this menu, you can change machine settings to adapt the machine
behaviour to difficult conditions.
Symbol Description
Lubrication interval of the centralised lubrication sys‐
tem
● 200 d: Set interval in strokes
● 55 a: Performed strokes
Switching between rod side and piston side feed
Rod side
Piston side
Simulated motor speed

(only for customer service)
Emergency stroke time

Colour Description
O Inactive
I Active
O/I Setting changed but not yet saved
Table 10: Setting status
If the core pump sensors are faulty, they can activate the emergency
stroke time. A standard value is entered for the stroke time.
You can change the emergency stroke time to adjust it to the pump‐
ing conditions.
Symbol Description
Reset the user settings to the standard values
Table 11: Function bar in the “User settings” menu
3.13.4 “Core pump” menu
The bar chart shows the core pump’s general operating parameters.

Symbol Description
Hydraulic fluid temperature
Current output in %
Current output in m3/h
You can adjust the output using the remote control.

The core pump condition is indicated by a simplified pictogram.
The pictogram contains the following information:

● Signals from the sensors on the drive cylinders
● Positions of the delivery pistons
The sensor signals are represented with colours.
Sensors on the drive cylinders:
Colour Description
Inactive
Active
Fault
Additional functions and messages are displayed on the left and right
edges. You can control the additional functions on the core pump op‐
erating panel.

Symbol Description
Centralised lubrication system
Lubrication procedure inactive
Lubrication procedure active
Centralised lubrication system fault
Vibrator
No vibrator connected
Vibrator Off
Vibrator On
Additional functions
You can switch functions on and off or switch them over in the func‐
tion bar. The availability of functions depends on the equipment of the
machine and the open menu.
The symbol lights up green if a function is active.


play
Compressor on/off
Fill-level sensor in the hopper on/off

Fill-level sensor off
Hopper filled
Hopper empty
Core pump stopped automatically
Switchover behaviour of the transfer tube
Automatic configuration
Hard switchover
Soft switchover
Working light on/off
3.13.5 “Motor” menu

The motor operating parameters are displayed in this menu.
Functions in this menu:

● Monitor the motor condition
● Monitor regeneration

The following operating parameters are displayed:
Symbol Description
Speed
Power supply
Fuel indicator
Double display
● Fill level (ratio)
● Consumption ( l/h)
Fill level low

Cooling water temperature
Engine oil pressure

Table 12: Operating parameters
The following information is displayed on the status of the exhaust af‐

ter treatment:

Symbol Description
Regeneration active
Table 13: Status of the exhaust after treatment
The machine is equipped with exhaust after treatment.

(Exhaust after treatment P. 3 — 21)
3.13.5.1 Motor fault codes
The last four motor fault codes are displayed in this list as a maxi‐
mum.
The fault codes are used for fault diagnosis when contacting our cus‐
tomer service.
This list is only displayed if there are faults.
3.13.6 “Inputs and outputs” menu
This menu is used for fault analysis when contacting the customer
service.
This menu is used to display the status of the connections on the con‐
trol cabinet.
Functions in this menu:

● Switch over the transfer tube manually

The connection designation in the circuit diagram is made up of the

connector (P1) and the pin.
Connector Pin Connection in circuit dia‐

gram
P1 03 10.3
P1 56 15.6
Table 14: Examples for connection designation
The pin status is indicated with colours:
Colour Description
Inactive/not present
Active
Fault
Row Description
pmSCP_C Control system software version
pmSCP_D Display software version
Table 15: Software versions

Symbol Description
Switch over the transfer tube
If actuated
Table 16: Function bar in the “Inputs and outputs” menu
3.13.7 “Operating data” menu
In this menu, the machine operating data is displayed in two ways:

● total: Operating data since manufacture
● trip: Operating data since daily meter was last reset
The daily meter has a white frame.
Symbol Description
Drive motor operating time
Hours, minutes, seconds
Core pump operating time
Hours, minutes, seconds
Number of strokes
Total and per minute
Pumped delivery rate

Symbol Description
Stroke duration 1
in seconds
Stroke duration 2
in seconds
You can reset the daily meter in the function bar.
Symbol Description
Reset daily meter (trip)
(press and hold for several seconds)
3.13.8 Messages
In case of doubt, contact the Putzmeister customer service.
Message Description Corrective measure

Messages active in the “Motor” Check the “Motor” menu for active messages.
menu
Table 17: Messages from the entire machine
3.13.8.1 Entire machine

EMERGENCY STOP active (EMERGENCY STOP function P. 3 — 8)
Table 18: Messages from the entire machine

3.13.8.2 Motor
Motor messages are triggered by a fault signal from the motor. The
fault signal is sent from the motor to the control cabinet.
Reference may be made to the motor manufacturer’s operating in‐

structions (included).

Motor control system reports See operating instructions from the motor manu‐
warning facturer
(included)
Rectify the special status during the next cleaning
operation
Motor control system reports fault Rectify the fault immediately
(critical) See operating instructions from the motor manu‐
Consequential damage if ignored facturer
(included)
Battery is not charging Check dynamo
Engine oil pressure outside stand‐ 1. Check engine oil filter

ard range 2. Check engine oil pump
Engine oil temperature too high 1. Check engine oil radiator and clean if necessa‐
ry
2. Check engine oil fill level
Cooling water fill level low Top up cooling water
Rectify the cause
See operating instructions from the motor manu‐
facturer
(included)
Fuel filter blocked Repair fuel filter
Table 19: General


● DPF full: Level 1 -
● Regeneration active
● DPF full: Level 2 1. Check whether regeneration was started auto‐
● Regeneration active matically
2. Start regeneration
(Exhaust after treatment P. 3 — 21)
● DPF full: Level 3 Have regeneration started by the motor manufac‐
● Regeneration active turer’s customer service
DPF full: Level 4 Have diesel particle filter replaced by motor manu‐
facturer’s customer service
Regeneration active -
Motor speed increased for regen‐
eration
Table 20: Diesel particle filter

Fault in exhaust after treatment Contact motor manufacturer’s customer service
system Where applicable, have the displayed SPN fault
Next escalation level in no more numbers to hand
than three hours
Fault in exhaust after treatment 1. Stop site use
system 2. Contact motor manufacturer’s customer service
Power reduced: Level 1 Where applicable, have the displayed SPN fault
numbers to hand
Fault in exhaust after treatment 1. Stop site use immediately
system 2. Contact motor manufacturer’s customer service
Power reduced: Level 2 Where applicable, have the displayed SPN fault
numbers to hand
Table 21: Exhaust after treatment system

3.13.8.3 Core pump

Lubrication cycle unsuccessful 1. Check lubricant reservoir fill level
2. Check lubrication lines for damage
3. Check lubricant distributor
(on hopper)
Hydraulic fluid fill level low Top up hydraulic fluid
Hydraulic fluid temperature too Check hydraulic fluid radiator and clean if neces‐
high sary
Fault on core pump sensors Contact customer service
Agitator safety cutout active (Agitator safety cutout P. 3 — 11)
Table 22: Core pump
3.14 Cable remote control
3.14.1 Structure
LEDs are integrated in the buttons on the cable remote control.
(Colour definition – LEDs in the button P. 3 — 24)

Item Designation
1 EMERGENCY STOP button
2 Grip
3 Hand guard
4 Operating panel
Button Function
● Deactivating the EMERGENCY STOP
● Horn
Loading the last saved core pump parameters
Forward pumping On/Off
Reverse pumping On/Off
Increasing output
Reducing output

Button Function
Increase motor speed
Reduce motor speed
3.14.2 Safely using the remote control
1. Only use the remote control if it is undamaged.

2. Carry the remote control on your person while the machine is
ready for operation.
3. Carry the remote control in such a way that no control elements
can be actuated unintentionally.
4. Maintain visual contact to the site of concrete placement, the ma‐
chine and to the work and danger zones.
5. If required, call in other persons who have visual contact to the
site of concrete placement, the machine and to work areas and
danger zones.
You need to set down the remote control?

1. Switch off the remote control.
2. Remove the cable on cable remote controls.
3. Lock the remote control away.

3.15 Core pump
3.15.1 Structure
Figure 11: Structure of the core pump – example illustration
Item Designation
1 Drive cylinder
2 Water box
3 Delivery cylinder
4 Delivery piston
5 Transfer tube
6 Hinged elbow on the pressure connection
7 Agitator
8 Hopper
3.15.2 Function
The core pump is powered by a diesel engine or an electric motor via

a hydraulic fluid pump. The delivery pistons are connected hydrauli‐
cally with each other via the drive cylinders. They run in counter
stroke.
Sequence of one stroke:

1. The returning delivery piston sucks the medium in.

At the same time, the advancing delivery piston pushes the medi‐
um previously sucked in via the hinged elbow or the pressure con‐
nection into the delivery line.
2. At the end of the stroke, the transfer tube swings in front of the fil‐
led delivery cylinder.
3. The core pump switches over.
4. The delivery pistons reverse their direction of movement.
3.15.3 Reversal
“Reversal” refers to a reversal of direction of the delivery pistons in

the middle of the stroke movement. The transfer tube does not switch
over as a result of this. The medium is reverse pumped out of the de‐
livery line and into the hopper.
3.15.4 Changeover
“Changeover” refers to a reversal of direction of the delivery pistons in

the middle of the stroke movement. The transfer tube switches over
as a result of this. The medium is still pumped without interruption.
The change-over helps to prevent the formation of a blockage.

3.15.5 Water box
3.15.5.1 Structure
Figure 12: Structure of the water box
Item Designation
1 Lid
2 Seal
3 Grille
4 Water outlet
5 Water box
3.15.5.2 Function
The water in the water box cools the core pump cylinders.

NOTICE
Risk of overheating of the concrete pump if the water box fill level is
low
1. Check the water fill level in water box regularly.
2. As required, fill the water box with cold, clean water in order to
prevent the concrete pump from overheating and consequential
damage.
3. You must rectify damage to the delivery piston/drive cylinders
immediately. Putzmeister accepts no warranty claims for dam‐
age to the machine resulting from failure to properly observe
the maintenance regulations.
4. When draining the water box, check the condition of the water –
particularly that it is clean.
The water in the water box must be replaced daily.
The water must be drained overnight to prevent corrosion.
3.15.5.3 Filling the water box
Prerequisites:
1. Remove the lid from the water box.

2. Make sure that water outlet for the water box is closed.
You can fill the water box with a water hose.

3. Fill the water box.
⇒ The water level in the water box is above the cylinder open‐
ings.
4. Stop the water supply.
5. Fit the lid on the water box.

3.15.5.4 Draining the water box
CAUTION
Risk of burning due to hot water in the water box
1. Exercise the necessary caution when working on the water box.
2. Allow the water to cool before carrying out maintenance work
1. Place a container underneath the water outlet point of the water

box.
2. Remove the lid.
3. Open the water outlet.
⇒ The water drains out.
4. Slowly move the delivery pistons until the water has drained com‐
pletely.
5. Check the condition of the water.
⇒ The water is clear or slightly cloudy.
There is a visible oil film on the water?

The drive cylinder seals are worn.
▶ Replace the drive cylinder seals.
The water is very cloudy and chalky white?

The delivery pistons may be worn.
1. Check whether there are grout deposits in the water box.

2. If necessary, replace the delivery pistons.
6. Dispose of the collected water.


3.15.6 Agitator
3.15.6.1 Structure
Item Designation
1 Mixing paddle
2 Mixer shaft
3 Agitator drive
3.15.6.2 Function
The hopper is equipped with a hydraulically driven agitator.
The agitator performs the following functions:

● Improving the fill level of the delivery cylinders
● Mixing the conveyed medium
The agitator and water pump are mutually locked. Only one of the
functions can be active at any one time.

Forward pumping:
The fill level in the delivery cylinders should be high. The
conveyed material is moved to the delivery cylinders by the
agitator.
Reverse pumping:
The delivery cylinders should be emptied. The conveyed
material is moved away from the delivery cylinders by the
agitator and mixed in the hopper.
3.15.6.3 Operating the agitator
Prerequisites:
✓ You have familiarised yourself with the agitator functions.
(Function P. 3 — 53)
You can supply the agitator or water pump with hydraulic fluid using a
lever.
If it had already been switched on, the agitator will start rotating as
soon as it is supplied with hydraulic fluid.
1. Turn the lever to the agitator.
You can operate the agitator from the following locations:

● Core pump operating panel


2. Switch the agitator to the required function.
⇒
/
3. Press the selected function again to stop the agitator.
3.15.7 Vibrator
The vibrator is bolted onto the hopper grille. It displaces the grille
when there is vibration, thereby preventing bridges from forming on
the grille, particularly in the case of very stiff concrete.
The vibrator is electrically driven. The coupling plug must be inserted

into the corresponding round socket.
The round socket is located at the control cabinet.
Figure 13: Vibrator structure
Item Designation
1 Grille
2 Vibrator
3 Supply line
4 Plug
You can switch the vibrator on and off at the following locations:

3.15.8 Magnetic switch distributor casing
The distributor casing for the magnetic switches is located on the

drive cylinders of the concrete pump.
There are two magnetic switches on each drive cylinder of the core
pump, one at the rod side and one at the piston side.
3.15.8.1 Structure
2
1
4
3
1
Figure 14: Structure of the magnetic switch distributor casing
Item Designation
1 Schematic illustration of the magnetic switch installation locations and
numbering
2 Schematic illustration of the plate on the distributor casing
3 Magnetic switch distributor casing with indicator lights: One yellow LED
per connection, one green LED for the housing (in service light)
3.15.8.2 Function
These switches trigger the switchover procedure when the drive pis‐
tons approach the magnetic switches. The indicator lights for the
magnetic switches that have just been triggered light up on the dis‐
tributor casing at the same time.
The magnetic switches and their functions are monitored by the pump
control system software. The distributor casing also provides a visual
display of the functions.

3.15.8.3 Indicator lights
Indicator light Magnetic switch status

lights up briefly during switch‐ Magnetic switch is OK
over
does not light up during switch‐ Magnetic switch, connector or
over lead are defective, replace at
the earliest opportunity
lights up continuously Magnetic switch, connector or
lead are defective, remove con‐
nector from the switch (other‐
wise switchover is not possible)
and replace at the earliest op‐
portunity
In service light Distributor casing status

Lights up continuously The distributor casing is ready
for operation.
Does not light up The machine ignition is switched
off.
Other LEDs are located on the magnetic switch connector. Using

these LEDs, you can detect whether the magnetic switch or con‐
nector (with lead) are defective.
(Magnetic switch connector P. 3 — 58)

3.15.9 Magnetic switch connector
The connector for the magnetic switch has one yellow and one green
LED. These LEDs indicate the status of the connector and the mag‐
netic switch.
1 2
Figure 15: Magnetic switch connector
Item Designation
1 Green and yellow LEDs
2 Connector
3 Magnetic switch
3.15.9.1 Significance of the LEDs
The yellow LED indicates the status of the magnetic switch, the green
LED indicates the status of the connector and the lead.

Yellow LED Magnetic switch status

lights up briefly during switch‐ Magnetic switch is fully function‐
over al
does not light up during switch‐ Magnetic switch is defective, re‐
over place at earliest opportunity
lights up continuously Magnetic switch is defective.
Disconnect the magnetic switch
connector (because otherwise it
is not possible to switch over)
and replace it at the earliest op‐
portunity
Green LED Connector and lead status

lights up there is power in the connector,
i. e. the connector and lead are
fully functional
does not light up there is no power in the connec‐
tor, i. e. the connector or lead is
defective or the fuse on the cen‐
tral control cabinet has been
triggered.

3.16 Centralised lubrication system
3.16.1 Structure
Item Designation
1a Lubricant reservoir
1b Air bleeder
1c Lubricant pump
2 Grease gun
3 Lubricant distributor
4 Mixer shaft bearings
5 Stransfer tube bearing
6 Upper switch cylinder bearings
7 Lower switch cylinder bearings
8 Switching shaft bearings
3.16.2 Function
The centralised lubrication system is automatic. The machine is lubri‐

cated in programmed intervals.
You can set the lubrication intervals in the software.

(“User settings” menu P. 3 — 33)

The following assemblies are lubricated by the centralised lubrication

system:
● Core pump
3.16.3 Maintaining the centralised lubrication system
1. Check at regular intervals whether lubricant is emerging at all lu‐

brication points.
2. Check the main lines and lubrication point lines for damage.
3. Replace the lines if necessary.
4. Never pump the container until it is completely empty.
Dirt in the system leads to faults.
5. Keep the system clean.
3.16.4 Filling the lubricant reservoir
The lubricant reservoir may be filled up to the “MAX” marking via the
filling nipple or from above through the filler opening.
Prerequisites:
✓ The machine is switched off.
CAUTION
Risk of injury
The lubricant reservoir could burst if it is overfilled.
▶ Only fill the lubricant reservoir up to the “MAX” marking.

CAUTION
Risk of injury
Risk of being drawn in or risk of crushing when reaching into the lu‐
bricant reservoir while the lubricant pump is pumping.
▶ Never reach into the lubricant reservoir while the lubricant pump
is running.
1. Open the air bleeder.

2. Use only a grease listed in the lubricant recommendation table.
3. Using the filler opening at the top, fill the lubricant reservoir with
grease up to the “MAX” marking.
4. Close the air bleeder.
➙ You have filled the lubricant reservoir.
3.16.4.1 Filling the lubricant reservoir using a grease gun
In many cases, the filler nipple of the lubricant reservoir is exten‐

ded with a hose and fastened to the truck superstructure so that
the lubricant reservoir can be filled more easily.
1. Connect a grease gun to the filler nipple on the lubricant reser‐

voir.
2. Open the air bleeder.
3. Via the filler nipple, fill the lubricant reservoir with grease up to
the “MAX” marking.
4. Close the air bleeder.
3.16.5 Additional lubrication procedure
You can cause an additional lubrication cycle to run if your machine is

to be run under particularly heavy loading.
An additional lubrication procedure is only possible if there is no

fault present.

You can trigger a manual lubrication at the following operating posi‐

tions:
● In local operation:
● At the core pump operating panel

4 Transport, support and connection

Transport, support and connection
4.1 Transporting
4.1.1 Loading
WARNING
Risk of death
The machine can fall from the lifting equipment if it is lifted incorrect‐
ly.
1. Check the gross weight of the machine before loading it.
2. Only use suitable and checked lifting eyes for lifting the ma‐
chine.
3. Only use suitable and undamaged auxiliary lifting and loading
equipment.
4. Pay attention to the geometry of the lifting tackle.
WARNING
Risk of death
Risk of death due to loads falling if auxiliary loading equipment is
damaged or not loaded correctly.
1. Never walk under suspended loads.
2. Only load the machine by crane if it is equipped with suitable
lifting points.
3. Ensure that lifting equipment, support trestles and other auxili‐
ary devices are reliable and safe in operation.
4. Make sure that the load-bearing capacity is sufficient.
Prerequisites:
✓ You have cleaned the machine.
(Cleaning P. 5 — 30)
✓ You have checked the gross weight of the machine.
✓ The machine accessories are secured.
1. Support the machine with the support wheel or the support feet.

Item Designation
1 Attachment bracket
2 Lifting points for lifting tackle
2. Hook four-cable lifting tackle to the four lifting points.

3. Tension the lifting tackle.
⇒ The four cables are attached at an angle of max. 45° to the
perpendicular.
The machine may swing if it is not lifted straight up.

4. Lift the machine vertically.
5. Load the machine on a horizontal surface.
The eyes suitable for lashing the machine are marked.

Figure 16: Marked eyes for lashing
If you are preparing the machine for transport:

6. Lash the machine down to the truck bed of the transport vehicle
or into the container using suitable auxiliary devices.
7. Remove the lifting tackle.
➙ You have loaded the machine.
4.1.2 Driving
The core pump must be empty while driving.
Designation Value
Maximum permissible speed 8 km/h
The machine must only be transported on a transport vehicle in road

traffic.
4.2 Supporting the machine
4.2.1 Checking the setup site
1. Ask the site management what the permitted ground pressure is.
2. Carefully inspect the intended set-up site.
3. Reject the set-up site if you have any doubts in respect of safety.

The approach route to the concrete pump must be sufficiently firm for
it to be driven over by truck mixers regardless of the weather condi‐
tions.
4. Walk the approach route before you drive along it.
5. Ask for a signaller if you need to reverse.
6. When approaching the set-up site and supporting the machine,
maintain a clearance from trenches, slopes and pits, etc.
You require space around the machine, in particular for the following
activities:
● Opening the guards, flaps and hoods
● Manoeuvring truck mixers
● Emptying two truck mixers simultaneously at the hopper
● Maintenance
7. Make sure that the machine is accessible from all sides.
The setup site must have sufficient lighting to ensure safe operation
of the machine.
8. Ensure that the setup site is adequately lit.
It must be possible for waste water to drain away (particularly in pits).

9. If necessary, use a waste water pump.
10. Ensure that the set-up site is adequately ventilated.
If adequate ventilation cannot be ensured:
11. Divert exhaust gas away from the workplace (e.g. using an ex‐
haust hose).
12. Make sure that there is a sufficient clearance from other ma‐
chines, combustible materials and flammable liquids.
If your machine is fitted with exhaust after treatment:
13. Only set up the machine if the exhaust heat created by exhaust
after treatment (approx. 600 °C) can escape.
4.2.1.1 Minimum clearance from pits
When supporting the machine, a minimum clearance from pits must

always be maintained.

WARNING
Risk of death due to the machine slipping
Risk of injury to various parts of the body by crushing, impact and
shearing caused by the machine slipping. If the supporting ground
has insufficient load-bearing capacity or there is inadequate clear‐
ance from pits or slopes, the machine will no longer be stable.
1. Check the condition of the supporting ground.
2. Use suitable support plates and timber blocks.
3. Check the maximum support loads that occur and the loadbear‐
ing capacity of the supporting ground.
4. Maintain a sufficient distance from pits and slopes.
The support load is conically diffused in the ground at an angle of 45°.

This imaginary cone must not exit through the wall of the pit.
The minimum clearance “a” is calculated as follows for machines:

● Up to a gross weight of 12 t, the minimum clearance is 1 m.
● Above a permissible gross weight of 12 t, the minimum clearance
is 2 m.
45°
Figure 17: Minimum clearance a
▶ Maintain the minimum clearance “a” even for a low-depth pit and
ground with a high loadbearing capacity.

4.2.1.2 Safe clearance from pits
The safe clearance A

● for loose, backfilled soil is A ≥ 2 × pit depth T.
● for compact, undisturbed soil A ≥ 1 × pit depth T.
A 2 T A 1 T
Figure 18: Safe clearance A
▶ Maintain the additional safe clearance A.

4.2.1.3 Supporting ground
WARNING
Risk of death due to a loss of machine stability
Risk of death and injury to various parts of the body by crushing, im‐
pact and shearing caused by loss of machine stability because the
supporting ground has insufficient load-bearing capacity.
1. Check the condition of the supporting ground.
2. Observe the notes on maximum support loads that occur.
3. Set up the support plates so that they are straight.
4. Provide support legs with horizontal supporting ground and, if
required, use timber blocks.
5. Ensure that there are no voids underneath the support feet.
6. Ensure that there are no areas of uneven ground underneath
the support feet.
7. Regularly observe the machine support strategy during opera‐
tion.
Figure 19: Do not support the machine on unsuitable supporting ground surfaces

Figure 20: Only support on level supporting ground
4.2.2 Support structure
Item Designation
1 Rear support feet
2 Crank
3 Rotating support
4 Forward support foot
5 Towing ring

Item Designation
1 Lever for support foot control
(for each side)
2 Enabling valve for support foot control
3 Rear support feet
Symbol Meaning
Lower support foot
Raise support foot
4.2.3 Extend supports
Prerequisites:
✓ You have read the safety regulations.
(Safety regulations P. 2 — 1)
✓ You have inspected the set-up site.
(Checking the setup site P. 4 — 5)
✓ The machine is horizontal.
4.2.3.1 Setting up the machine
1. Secure the wheels with chocks.

In order to support the machine with the rotating support, you must
fold the support wheel down.
2. Fold the support wheel down.
You can raise or lower the rotating support using the crank on the
drawbar.
3. Lower the rotating support.
4.2.3.2 Lowering the rear support feet
1. Raise the rotating support.

⇒ The drawbar moves downwards.

⇒ The rear of the machine moves upwards.
2. Place support plates underneath the rear support feet.

3. Pull the spring pins out of the stop pins on the rear support feet.
The support feet may move downwards on their own as soon as you
pull out the stop pin.
4. Hold on to the lower part of the support foot while pulling out the
stop pin.
The machine should be level once supported.
The following components must be on one level:

● Support feet
● Wheels
5. Pull out the support foot.
6. Lock the support foot with the stop pin.
7. Secure the stop pin with the spring pin.
8. Repeat the procedure for the support foot on the other side.
9. Lower the rotating support.

⇒ The front of the machine moves upwards.

⇒ The machine is supported on the rear support feet.
⇒ The load on the wheels is relieved.
4.2.3.3 Folding down the support foot
If the forward support foot is folded up, you need to fold it down.
Figure 21: Forward support foot in the folded down position
Item Designation
1 Stop pin
1. Pull the spring pin out of the marked stop pin on the forward sup‐
port foot. (1)
2. Pull out the stop pin.
3. Fold down the support foot.
4. Lock the support foot with the stop pin.

➙ You have folded down the support foot.
4.2.3.4 Lowering the forward support foot
1. Place a support plate underneath the forward support foot.

2. Pull the spring pin out of the stop pin on the forward support foot.
3. Pull out the stop pin.
4. Pull out the forward support foot.
5. Lock the forward support foot with the stop pin.

7. Raise the rotating support.
➙ You have supported the machine.
When pumping with high pressure, pump pulsations could interfere

with the stability of the machine. The support feet can be anchored to
the ground (for example by setting them in concrete or lashing them
down with tensioning chains) to provide the machine with greater sta‐
bility.

4.2.4 Retracting the supports
Prerequisites:
✓ You have read the safety regulations.
(Safety regulations P. 2 — 1)
✓ There is no conveyed material in the hopper.
✓ You have cleaned the machine.
1. Lower the rotating support if necessary.

⇒ The load on the forward support foot is relieved.
2. Raise the forward support foot.
3. Fold up the forward support foot.
4. Raise the rotating support by a few centimetres.
⇒ The front of the machine moves downwards.
⇒ The load on the rear support feet is relieved.
5. Retract the rear support feet.
6. Make sure that all support feet are locked and secured.
➙ You have retracted the support.

5 Operation
This chapter describes a site use, as an example.

Operation
5.1 Test run

The machine may have been damaged in your absence. You will be
well prepared if you check the condition of the machine before driving
to the construction site.
1. Make sure that all safety devices are fitted.

2. Check the machine for leaks.
3. Check the machine’s wear parts and accessories (in particular
cleaning accessories) for wear.
4. Replace worn components.
6. Support the machine.
7. Check the machine functions.

⇒ (Checking the functions P. 5 — 9)
5.2 Starting up
Prerequisites:
✓ When taking over the machine, you have become so familiar with
the device that damage and accidents caused by incorrect opera‐
tion cannot occur.
1. Make sure that all delivery line couplings are secured.

2. Make sure that there are no loose objects on the machine which
could fall down.
5.2.1 Checking the machine for damage
The deployment of a damaged machine for site use may lead to long-
term consequential damage.
Separating protective device prevent people coming into contact with

a source of danger.

Operation
Examples of separating protective devices:

● Grille
● Spray guard
● Protective grille
● Heat protection plate
1. Replace damaged separating protective devices.

2. Check the machine for visible damage.
For some assemblies, simply rectifying external damage is insuffi‐

cient. Measures for typical damage are listed below.
Damaged assembly Corrective measure

Agitator drive Check the concentricity of the
mixer shaft
(see service instructions)
Vibrator ● Check that the vibrator is
functioning correctly and re‐
pair it if necessary
● Check the grille for cracks
and repair it if necessary
Support leg Contact the After Sales depart‐
ment
Aerial Replace the assembly
3. Implement the recommended measure in case of damage.

4. In case of doubt, contact the After Sales department.

Operation
5.2.2 Draining the hydraulic fluid reservoir
NOTICE
Corrosion damage in the hydraulic system caused by excessive wa‐
ter content
Corrosion damage can lead to increased wear or even to machine
damage.
▶ Drain the condensation each time before starting work.
NOTICE
Environmental pollution caused by incorrect condensation removal
The drained liquid is an environmentally damaging mixture of water
and hydraulic fluid.
1. Dispose of this mixture properly.
2. Empty the catching container properly so that it does not over‐
flow and so that the environment is not contaminated.
Condensation collects in the hydraulic fluid reservoir after lengthy ma‐

chine downtimes (e.g. overnight).
The hydraulic fluid reservoir is dewatered via the fluid drain cock.
The fluid drain cock is on the bottom of the hydraulic fluid reservoir.
1. Place a suitable container underneath to catch the condensation.
2. Open the fluid drain cock on the hydraulic fluid reservoir.
⇒ The collected condensation drains out.
⇒ Once the condensation has drained out, hydraulic fluid will
start draining.
3. Close the fluid drain cock on the hydraulic fluid reservoir.
4. Dispose of the water in accordance with local environmental reg‐
ulations.

Operation
5.2.3 Checking functional fluids
WARNING
Hazardous auxiliary materials or functional fluids
Possible poisoning, chemical burns or irritation
1. Take note of the safety data sheets for the auxiliary materials
and functional fluids used.
2. Wear personal protective equipment.
3. Personnel who work with auxiliary materials or functional fluids
must be trained in handling them.
Prerequisites:
✓ The machine is horizontal.
✓ The supports are retracted.
✓ The water box is filled.
The water box must be filled during operation, even if there is a

risk of freezing. The water box must be empty overnight to prevent
corrosion.
MAX
MIN
MAX
MIN
Figure 22: Water, oil and fuel levels

Operation
● Fuels
(for combustion engines)
● Motor oil
● Cooling water
● Hydraulic fluid
● Lubricant of the centralised lubrication system
1. Allow the functional fluids to cool.
2. Check the fill levels of all functional fluids.
3. Refill the functional fluids if necessary.
There must always be a little fuel in all fuel tanks to prevent corro‐
sion.
5.2.4 Switching on the machine
Prerequisites:
✓ You have checked the machine for damage.
(Checking the machine for damage P. 5 — 3)
✓ You have checked the functional fluids.
(Checking functional fluids P. 5 — 6)
✓ The machine's operating positions are not being actuated.
✓ The machine is supported.
(Supporting the machine P. 4 — 5)
1. Open the side flaps.
The “Motor On/Off” keyswitch is located on the control cabinet.
2. Switch the engine on.

⇒ The drive motor starts up.
⇒ The control system is switched on.
If an EMERGENCY STOP button has been pressed:
3. Unlock the EMERGENCY STOP button. (Checking the EMER‐
GENCY STOP function P. 3 — 10)

Operation
4. Deactivate the EMERGENCY STOP.

➙ You have switched on the machine.
You can carry out the function checks.
5.2.5 Warming up the hydraulic fluid
Starting up the machine requires a warm-up period if the temperature

of the hydraulic fluid is below 0 °C.
Prerequisites:
✓ The drive motor is switched on.
✓ The core pump is switched off.
▶ Let the machine idle for a few minutes.

⇒ The temperature of the hydraulic fluid (VG 46) is at least
10 °C.
Ideal hydraulic fluid temperature (HLP or HEES, VG 46): 40 °C to

70 °C
5.2.6 Deactivating the EMERGENCY STOP

rectified.
2. Turn the pressed EMERGENCY STOP BUTTON.

⇒ You have unlocked the EMERGENCY STOP button.
3. Press the “Deactivate EMERGENCY STOP” BUTTON.
➙ The EMERGENCY STOP is deactivated.

Operation
5.2.7 Deactivating the agitator safety cutout
WARNING
is intact.

up the machine and when the agitator safety cutout has been activa‐
ted, you must deactivate the agitator safety cutout for the core pump
to work.
1. Make sure that there is only conveyed material in the hopper.

You can deactivate the agitator safety cutout on the core pump oper‐
ating panel.
3. Press the “Deactivate agitator safety cutout” BUTTON.

➙ The stroke correction is started up.
➙ You have deactivated the agitator safety cutout.
You can switch on the core pump.
5.3 Checking the functions

You must check the following functions before you begin site use.
If you have already carried out a test run before the site use, it is
not necessary to check the functions again.
(Test run P. 5 — 3)

Operation
5.3.1 Checking the EMERGENCY STOP function
WARNING
Risk of death due to a defective EMERGENCY STOP button
The machine cannot be switched off quickly enough in the event of
impending danger if the EMERGENCY STOP button is defective.
This means that the machine is no longer safe to use.
▶ Check that the EMERGENCY STOP button is working properly
before starting work each time.
It is only possible to intervene quickly in the event of danger if all the

EMERGENCY STOP buttons are working properly.

Figure 23: EMERGENCY STOP button
Item Designation
1 Press: Locks EMERGENCY STOP button
2 Turn: Unlocks EMERGENCY STOP button
4. Press one of the EMERGENCY STOP BUTTONS.

Operation
⇒ All safety actions are carried out immediately.

Area Action
tion
trically
5. Check all EMERGENCY STOP buttons on the machine.

6. Check all EMERGENCY STOP buttons on the cable remote con‐
trols.
5.3.2 Checking the agitator safety cutout
WARNING
is intact.

Operation
Figure 24: Agitator safety cutout function check
2. Open the grille.
tions
⇒ A message is shown on the display:
The safety actions are not carried out?

3. Have the agitator safety cutout repaired.

⇒ (Deactivating the agitator safety cutout P. 3 — 13)

Operation
➙ You have checked the agitator safety cutout.
5.3.3 Checking the pump functions
Only use the pump if you cannot detect any visible damage to the
pump or adjacent components.
5.3.3.1 Checking the switchover
▶ Check for an unimpeded switchover function of the delivery pis‐

tons and the transfer tube at various engine speeds and positions
of the output controller.
5.3.3.2 Magnetic switch
Figure 25: Checking the magnetic switches
▶ Check whether the drive cylinders switch over automatically as

soon as the hydraulic pistons approach the magnetic switch.
⇒ The green in service light on the distributor casing lights up
permanently.
⇒ The yellow LEDs light up briefly as soon as the hydraulic pis‐
tons approach the relevant magnetic switch.
If one of the LEDs does not light up, the magnetic switch is defec‐
tive.

Operation
5.3.3.3 Checking the stroke length
▶ When the delivery pistons are moving slowly, press and hold the
CHANGE-OVER BUTTON on the remote control.
⇒ The delivery pistons move to their end positions.

⇒ Stroke correction is automatic and is complete when both de‐
livery pistons come to a halt (may be seen in the water box).
5.3.3.4 Checking the stroke time
Measure the machine stroke time under no load, i.e. without concrete.
1. Set the engine to maximum speed.
2. Set the maximum output.
3. Start the measurement when the transfer tubes are switched over
for the first time.
⇒ The next time the transfer tubes are switched over, the first
single stroke is complete.
4. Take the measurement over a period of 10 single strokes.
⇒ The measured value divided by 10 must be the same as the
data in the test reading.
Due to differences in reaction times when using the stopwatch, the

value determined may vary from the value stated by approximately
5%. You may have to take the measurement several times and
calculate the mean of the values measured.
5.3.4 Checking the hydraulic fluid filters
Clogged hydraulic fluid filters reduce the hydraulic fluid flow consider‐
ably with the result that damage may occur in the hydraulic system.

Operation
5.3.4.1 Check the contamination indicator
The pressure gauge is located near the control cabinet.
Figure 26: Pressure gauge for filter condition
Prerequisites:
✓ The water box is filled with water.
✓ The machine is switched on.
✓ The temperature of the hydraulic fluid is at least 50 °C.

2. Check the pressure gauge.
⇒ The indicator for the pressure gauge is in the green area.
The indicator is in the red area?

The pressure filter impedes the flow of the hydraulic fluid.
▶ Replace the pressure filter.
5.3.4.2 Checking the pressure filter
Prerequisites:
✓ The water box is filled with water.
✓ The machine is switched on.
✓ The temperature of the hydraulic fluid is at least 50 °C.
The pressure filter is located behind the control cabinet.


Operation
Figure 27: Checking and replacing the pressure filter
2. Press the red button on the pressure filter.

⇒ The red button remains down.
The red button pops back out?

▶ Replace the pressure filter.
5.4 Hand signals for pumping operations

Clear hand signals must be agreed between the machine operator
and the signaller before start of work. Suggestions for the most impor‐
tant hand signals are made in this chapter. The direction of move‐
ment should be taken to be from the direction of view of the machine
operator.

Operation
5.4.1 EMERGENCY STOP hand signal
Figure 28: EMERGENCY STOP
▶ With your arms stretched out to the side, move both arms quickly
up and down.
5.4.2 Hand signal for stopping
Figure 29: Stop
▶ Stretch both arms out to the side.

Operation
5.4.3 Hand signal for increasing output/start of delivery
Figure 30: Increasing output or start of delivery
1. Point the thumb on one hand upwards.

2. Hold the palm of the other hand over it.
5.4.4 Hand signal for reducing output
Figure 31: Reducing output
1. Point the thumb on one hand downwards.

2. Hold the palm of the other hand under it.

Operation
5.4.5 Hand signal for reverse pumping
Figure 32: Reverse pumping
▶ With one arm crooked, place your elbow into the palm of your
other hand.
5.4.6 Hand signal for stopping the pump
Figure 33: Stop pump
▶ Hold both arms above your head with your hands clasped togeth‐
er.
5.5 Filling the water box

Prerequisites:
1. Remove the lid from the water box.

2. Make sure that water outlet for the water box is closed.
You can fill the water box with a water hose.

3. Fill the water box.

Operation
⇒ The water level in the water box is above the cylinder open‐
ings.
4. Stop the water supply.
5.6 Pumping
Prerequisites:
✓ You have started up the machine.
(Starting up P. 5 — 3)
✓ You have supported the machine.
✓ You have checked the functions.
(Checking the functions P. 5 — 9)
5.6.1 Dangers during pumping
Risks to the life and limb of site personnel can arise at many points
during pumping.
▶ Observe the safety instructions in order to minimise the risk of ac‐
cidents.
5.6.1.1 Sucking in air

Operation
Entrapped air can become compressed air at the end of the delivery
line, which can be released suddenly, ejecting the concrete violently.
1. Do not draw any air in.
Figure 34: Filling the hopper correctly
2. Always fill the concrete pump's hopper with concrete up to the

mixer shaft during the pumping process.
5.6.2 Notes on correct pumping
In addition to the instructions printed here, you will find detailed infor‐
mation on the following subjects in the “Concrete technology” bro‐
chure (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 can request a copy of this brochure from the Putzmeister After
Sales department.
5.6.3 Damping valve
The damping valve is used to control the switching speed of the

transfer tube.

Operation
Figure 35: Damping valve
Item Designation
1 Hare – damping valve switch position open
2 Snail – damping valve switch position closed
1. Close the damping valve (snail symbol) if you are pumping con‐
crete with a soft consistency, because otherwise the transfer tube
will switch over too vigorously.
2. Open the damping valve (hare symbol) if you are pumping con‐
crete with a stiff consistency, because the concrete has a cush‐
ioning effect.
5.6.4 Mixing together
Correct mixing together of concrete influences pumping.
1. Mix the concrete vigorously in the truck mixer at maximum speed

of rotation.
2. Ensure that the concrete mix is uniformly prepared.
3. Add concrete additives (deflocculants, set retarding admixtures)
and mix for at least a further four minutes.
5.6.5 Operating the agitator
Prerequisites:
✓ You have familiarised yourself with the agitator functions.

Operation
(Function P. 3 — 53)
You can supply the agitator or water pump with hydraulic fluid using a
lever.
If it had already been switched on, the agitator will start rotating as
soon as it is supplied with hydraulic fluid.
1. Turn the lever to the agitator.
You can operate the agitator from the following locations:

2. Switch the agitator to the required function.
⇒
/
3. Press the selected function again to stop the agitator.
5.6.6 Starting to pump
The process from the start of concrete pumping until the moment
when a continuously flowing concrete stream emerges from the end
hose is referred to as “starting to pump”.
You must start to pump with a cement-water mixture (grout) in the

following cases:
● Long delivery line (longer than 50 m)
● New delivery line
● Delivery line that has not been used for a long time

Operation
Prerequisites:
✓ The machine is supported.
✓ You have filled the water box.
You must wet the entire delivery line at the start of pumping opera‐
tions.
Figure 36: Starting pumping with thin concrete
1. Insert two sponge balls into the delivery line through the wash-out
port.
The following volume of thin concrete is recommended depending on

the length of the delivery line:
Delivery line length Required volume

0–100 m 0.5–0.7 m3
>100 m 1 m3
2. Make sure that nobody is in the danger zone by the end hose.
⇒ (End hose P. 2 — 10)
4. Fill the hopper with grout.
5. Pump the concrete slowly into the delivery line.
⇒ The process of starting to pump with thin concrete is comple‐
ted when the two sponge balls and a solid concrete stream ex‐
it from the end hose.

Operation
5.6.7 Starting the pumping process
Prerequisites:
✓ You have started to pump concrete.

3. Start with a low output and increase this continuously after sever‐
al cubic metres.
5.6.8 Checking the condition of the machine
The machine will become worn during pumping. Lubricants and func‐
tional fluids are consumed.
1. Check the condition of the machine during pumping.

2. Check whether the pressures are in the normal range.
3. Lubricate the core pump in shorter intervals if a cement-coloured
fluid or grease mixture emerges from the bearings on the hopper.
4. If necessary, to up the lubricants and functional fluids.
5.6.9 Breaks in pumping
You should avoid breaks in pumping as far as possible, as the con‐

crete in the delivery line can start to set, or can become segregated
due the vibrations of the machine. Note the following points if breaks
are unavoidable.
Poor concrete consistence can easily lead to blockages.

1. Never pump segregated concrete or concrete that has become
lumpy because it is beginning to set into the delivery line.
2. Relieve the delivery line during short breaks in pumping by re‐
verse pumping briefly (2–3 strokes).
3. Move the concrete at frequent intervals by forward and reverse
pumping.
4. Avoid breaks when pumping concrete with a low water retentivity
(tendency to bleeding) as the vibrations can segregate the con‐
crete.
5. In the case of lengthy breaks in pumping, pump the concrete
back into the hopper.

Operation
6. Mix up the concrete again before starting to pump once more.

7. When you begin the pumping process after breaks in pumping,
leave the concrete pump to pump in reverse until the transfer
tube switches through fully on both sides.
8. Switch off the core pump and reduce the output to “0” before
starting the engine.
5.6.10 Rectify any 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.
5.6.10.1 Blockage
Figure 37: Blockage
Item Designation
1 Wedged aggregate
2 Cement paste
3 Boundary layer
The following faults can lead to blockages:

● Delivery line insufficiently wetted
● Transfer tube leaking
● Delivery line leaking
● leavings in the transfer tube and delivery line
● unsuitable concrete composition
● segregated concrete
● set concrete

Operation
1. In the event of blockages, pump the concrete immediately back

into the agitator hopper and mix it up.
2. Switch back over to forward pumping if the delivery cylinders and
transfer tube are automatically switching over perfectly once
again.
3. Begin pumping again with care.
5.6.10.2 Motor overload
1. Make sure that the permissible motor speed is not exceeded.
The permissible motor speed is listed on the machine card and on

the machine rating plate.
2. Leave the drive motor switched on after heavy motor loads.

⇒ The drive motor cools down while idling.
5.6.10.3 Overheating
Continuous operation under high loading can lead to overheating of

the hydraulic fluid.
The following may cause the hydraulic fluid to overheat, particularly if

several factors coincide:
● Continuous operation under high load
● High ambient temperatures
● Too little hydraulic fluid in the hydraulic system
● Dirty hydraulic fluid radiator
● Insufficient radiator supply/exhaust air
● Hydraulic fluid radiator sucking in hot exhaust gases
● Excess pressure as a result of a blockage
● Too little water in the water box
Your machine has a thermoelectrical cutout. The machine is automat‐

ically switched off if the hydraulic fluid temperature exceeds the fol‐
lowing limit:
90 °C

Operation
To prevent the machine being switched off due to overheating of the

hydraulic fluid:
1. Check that the hydraulic fluid radiator is operating correctly.
2. Manually switch the hydraulic fluid radiator on again if it is not
working properly.
3. Reduce the output if the hydraulic fluid temperature is approach‐
ing the limit.
4. Pour fresh water into the water box immediately if the “Hydraulic
fluid temperature/sensor defective” symbol is displayed.
Cooling
NOTICE
Material damage
Water containing salt damages the core pump and the chrome layer
of the delivery piston rods and delivery cylinders.
1. Never spray the hydraulic fluid reservoir with water.
2. Never cool using sea water or water containing salt.
Figure 38: Cooling the hydraulic fluid
1. Continuously change the water in the water box if the hydraulic

fluid temperature continues to rise.
2. Locate the cause of the hydraulic fluid overheating and rectify this
cause.

Operation
Additional cooling
Figure 39: Additional cooling
▶ If additional cooling is required, direct the water jet towards the

drive cylinder and piston rods in the drive cylinder.
Restarting after overheating
Should the machine have been switched off because of overheating,

you should proceed as follows:

2. Do not switch the motor 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. Switch on the core pump and continue to pump at reduced out‐
put.
6. Determine the cause of the hydraulic fluid overheating once
pumping operations have been completed and rectify this cause.

Operation
5.7 Cleaning
WARNING
Moving parts in the hopper
1. Do not reach into the hopper.

2. Do not insert any objects through the grille.
3. Never operate the concrete pump without the grille in place.
4. Check the wear to the grille at regular intervals.
WARNING
is intact.
WARNING
Conveyed material can spray out
Injuries to skin and eyes
The delivery line may be pressurised even when the machine is
switched off.
1. Wear your personal protective equipment.
2. Only open the cleaning port if there are no persons directly in
front of it.
3. Dump the pressure in the delivery line before opening the
cleaning port.

Operation
WARNING
Risk of injury from the grille slamming shut
Risk of the upper body being crushed or suffering impact due to the
grille slamming shut.
▶ Always open the grille as far as it will go (i.e. to its end position)
and then secure it.
WARNING
WARNING
Risk of burning
Auxiliary materials and functional fluids can explode when atomiz‐
ed.
1. In the Operating Instructions, follow the safety instructions con‐
cerning highly explosive or atomized auxiliary materials or func‐
tional fluids (e. g. preserving agents).
2. Take note of the safety data sheets for the auxiliary materials or
functional fluids used.
3. During spraying or preserving, smoking and naked flames are
prohibited.
4. Always wear personal protective equipment.
Concrete residue can continue to build up, speeding up wear and po‐
tentially blocking the machine. The machine must therefore be
cleaned after each time the pump is used.

Operation
Concrete residues deposited around the wear ring can impair its func‐
tion. Therefore, thorough rinsing of the wear ring is important after
work is finished, as long as the pump will not be used again within the
next 30 to 60 minutes.
5.7.1 Observe the notes on cleaning
1. Lock the remote control units away in the driver’s cab during
cleaning operations if they are not being used for the cleaning
process.
2. Never clean the machine using salt water.
3. Rinse the machine immediately if it comes into contact with sea
water or salt water.
4. Do not use any aggressive cleaning agents.
5. Please note that the temperature of the washing water must not
be higher than 50 °C.
6. Maintain a minimum distance of 40–50 cm between the spray
nozzle and the painted surface.
In the first 8 working weeks, you must also ensure the following:
7. During the first 8 weeks, do not use any steam jet equipment, be‐
cause the paint is not yet fully dried.
8. Use only cold water for cleaning.
5.7.2 Cleaning preparations
We recommend that you carry out the preparations described below

in good time to allow you to clean the delivery line and the concrete
pump directly the site use is completed.

Operation
5.7.2.1 Pre-fitting the catch basket
The use of the catch basket is recommended when cleaning with

pressurised water, to ensure that the delivery line is sealed off, and
no water can escape.
Figure 40: Fitted catch basket
Item Designation
1 Coupling
2 Catch basket (closed pipe section)
3 Spring pin (on both sides)
4 Catch bracket
▶ Make sure that the catch basket is fully fitted.

⇒ The concrete can flow out unimpeded.
⇒ The wash-out sponge is caught, sealing the delivery line.
5.7.2.2 T delivery pipe with wash-out port
The T delivery pipe with wash-out port can be used when cleaning
with pressurised water. It allows the wash-out sponges to be inserted
quickly. It traps the wash-out sponge in suction cleaning.

Operation
WARNING
The delivery line is pressurised
1. Only open the wash-out port lid when the delivery line is dep‐
ressurised.
2. Make sure that the T delivery pipe is designed for the delivery
pressure specified on the concrete pump rating plate.
Item Designation
1 T delivery pipe with wash-out port
2 Wash-out port lid
5.7.2.3 Wash-out adaptor
The wash-out adaptor can be used when the machine is cleaned us‐
ing pressurised water or compressed air.
CAUTION
Risk of explosion
The connections and shut-off valves of the wash-out adaptor are
not designed for the pressure of a concrete pump.
▶ Only fit the wash-out adaptor for cleaning.

Operation
Figure 41: Wash-out adaptor structure
Item Designation
1 Pressure gauge
2 Guard bracket
3 Connection for pressurized water or compressed air
4 Shut-off valve for connection
5 Pressure dump elbow
6 Dump cock
1. Close the dump cock.

2. Close the connection for pressurised water or compressed air.

Operation
5.7.2.4 Preparing cement bags
When it comes to cleaning the delivery line with pressurised water,

rolled-up cement bags soaked in water are a tried and tested cleaner.
The cement bags prevent the washing water entering into the con‐
crete, rinsing it out and causing a blockage.
Figure 42: Rolled-up cement bags
1. Roll up one or two empty cement bags.

2. Before cleaning, immerse the rolled-up cement bags in water for
approximately five minutes.
Figure 43: Prepared pipe section
3. Before cleaning, prepare a short pipe section.

4. Fill it with the cement bags and two to three wash-out sponges.
5.7.2.5 Marking the water hose
For optimum cleaning of the wear ring and seal ring in the hydraulic
diversion valve, this area must be rinsed with water for quite a long
period from a short distance away. So that the water hose is not cut
off from the hydraulic diversion valve (which is switching over), you
must mark the water hose as described below.
Prerequisites:
1. Dump the hydraulic system.

Operation
Figure 44: Cleaning in the hopper
Item Designation
1 Adhesive tape marking
2. Measure the hose length required on the outside of the transfer

tube.
The hose spray nozzle should be located just in front of the wear
ring, so that concrete residue is washed out of the area of the wear
ring and seal ring when the spray is set.
3. Mark the measured length on the water hose with adhesive tape
or similar.
5.7.3 Using concrete residue
For reasons of environmental protection, you should always ensure

that concrete residue is put to good use.
1. Use the concrete residue on the construction site.

2. Only move the concrete residue to building rubble or a recycling
plant if you cannot use it on the construction site.
5.7.3.1 Transporting concrete residue with a sheet
1. Make sure that the sheet is suitable for the concrete residue load.

Operation
2. You should ideally use the concrete residue sheet from Putzmeis‐
ter.
3. Place the sheet underneath the hopper.
4. Open the cleaning flap on the hopper.
⇒ The concrete flows into the sheet.
You can use a construction site crane to transport the sheet to the
placement site.
5.7.3.2 Disposing of concrete residue
1. Bend a piece of construction steel into a hook.

2. Insert the hook into the concrete.
3. Leave the concrete to set.
4. Transport the set lump of concrete with a construction site crane.
5.7.4 Clean the delivery line
There are a number of options for cleaning a delivery line. Some of

the factors affecting which cleaning method you use include how the
concrete pump has been used and what equipment you have availa‐
ble.
5.7.4.1 Overview of the cleaning methods
This section describes the recommended cleaning methods for the

listed delivery lines.

Operation
Symbols
The delivery line is connected to the concrete

pump. The concrete residue is pumped by the con‐
crete 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 concrete residue is 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 concrete residue is forced for‐
wards from the start of the delivery line to the site of
concrete placement using an external force (com‐
pressed air or water under pressure). Cleaning is
from the start of the delivery line to the site of con‐
crete placement.
The delivery line has been disconnected from the
concrete pump. The concrete residue is forced
backwards from the site of concrete placement to
the start of the delivery line to using an external
force (compressed air or water under pressure).
Cleaning is from backwards from the site of con‐
crete 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

Operation
Stationary delivery line
Delivery line Cleaning

method
Horizontal line Compressed

air
Water under
pressure
Suction clean‐
ing
Riser Compressed only with spe‐
air cial equipment
Water under
pressure
Suction clean‐
ing
Downpipe Compressed only with spe‐
air cial equipment
Water under
pressure
Suction clean‐
ing
5.7.4.2 Suction cleaning
Suction cleaning is the simplest and least hazardous cleaning meth‐

od.
1. Pump until the hopper is as empty as possible.


Operation
Insert the wash-out sponge
Figure 45: Cleaning accessories
Item Designation
1 Sponge pig
2 Sponge cube
3 Sponge ball
4 Wash-out pig
▶ Push a water-soaked wash-out sponge into the end hose.
Reverse pumping the concrete
WARNING
Risk of injury
Concrete can spray out of the hopper during reverse pumping.
1. Wear protective goggles.
2. Wear respiratory protection.
▶ Switch the core pump to “reverse pumping”.

Operation
⇒ The concrete and the wash-out sponge are pumped back

through the delivery line.
The concrete is not pumped back?

The delivery line is too long for suction cleaning.
▶ Clean the delivery line by “Cleaning with pressurised water”.
Tracking the wash-out sponge
Figure 46: Tracking the wash-out sponge in the delivery line
1. Tap on the delivery line with a piece of hardwood (hammer han‐

dle) just ahead of the cleaning port during the washing out proc‐
ess.
⇒ If there is concrete in the delivery line, the tapping generates
deep, dull sounds. Once the concrete and wash-out sponge
have passed the tapping location, the tapping generates high-
pitched, clear sounds.
Only tap the delivery line with the hammer handle, as the delivery
pipe might be damaged otherwise.
2. Switch the core pump off as soon as the wash-out sponge has
passed the point at which you are tapping.

Operation
Trapping the wash-out sponge
Figure 47: Trapping the wash-out sponge with the pin at the wash-out port lid.
1. Unlock the movable pin on the wash-out port lid and push it into
the delivery line.
2. Switch the core pump to reverse pumping.
⇒ The wash-out sponge will be trapped on the movable pin.
4. Remove the wash-out port lid.
5. Remove the wash-out sponge.
6. Fit the wash-out port lid.
Reverse pumping a wash-out sponge once is not sufficient.

7. Repeat the washing out process.
8. Fit the wash-out port lid.
9. Pull out the pin from the delivery line and move it to the starting
position.
10. Secure the pin.
➙ You have cleaned the delivery line.

Operation
5.7.4.3 Cleaning with pressurised water
Cleaning with pressurised water is more thorough than suction clean‐

ing, but also requires more effort. The core pump or an auxiliary
pump can be used for cleaning with pressurised water.
Figure 48: High-pressure water cleaning
Item Designation
1 Gate valve
2 “Pump” delivery line
3 Container
Prerequisites:
✓ There is no end hose fitted at the end of the delivery line.
Dumping the pressure in the delivery line
1. Close the gate valve.

2. Place a container underneath the concrete pump’s hopper.
3. Switch the concrete pump to “Reverse pumping”.

Operation
4. Switch the concrete pump off after one to two strokes.

⇒ The pressure in the delivery line is dumped.
Inserting the wash-out sponge
1. Soak two to three wash-out sponges in water.

2. Push the wash-out sponges into the concrete pump's wash-out
port.
3. Close the wash-out port.
▶ Alternatively, you can prepare a pipe section with sponge balls
and cement bags and install it in the delivery line.
You can connect an auxiliary pump.
Connecting an auxiliary pump
1. Disconnect the concrete pump from the delivery line.

2. Connect the wash-out adaptor to the delivery line.
3. Connect an auxiliary pump (e.g. high-pressure water pump) to
the wash-out adaptor.
Pumping water
1. Fit a catch basket on the boom tip.

2. Fill the hopper with water.
3. Open the gate valve.
4. Switch the concrete pump to “Forward pumping”.
⇒ The concrete is pumped out of the delivery line.
The hopper content is insufficient?

The volume in the delivery line is larger than the hopper volume.
▶ Refill the water before air is sucked in.

Operation
Figure 49: Tracking the wash-out sponge
5. Tap on the delivery line with a piece of hardwood (hammer han‐

dle) just ahead of the cleaning port during the washing out proc‐
ess.
⇒ If there is concrete in the delivery line, the tapping generates
deep, dull sounds. Once the concrete and wash-out sponge
have passed the tapping location, the tapping generates high-
pitched, clear sounds.
6. Run the pump until the wash-out sponges emerge at the end of
the end hose.
7. Switch the pump to “Reverse pumping”.
8. Move the placing boom so that it is vertical.
⇒ The washing water can escape from the delivery line.
5.7.4.4 Cleaning with compressed air
You can use compressed air to facilitate cleaning of a long delivery

line if a wash-out tower or container is connected to the delivery line.

Operation
WARNING
Risk of injury when cleaning the delivery line with compressed air
1. Cleaning with compressed air must only be carried out by quali‐
fied personnel.
2. Inform all personnel involved in cleaning with compressed air of
the safety regulations.
3. Remove the end hose, if fitted.
4. Fit the catch basket onto the delivery pipe end before cleaning
with compressed air.
5. When cleaning with compressed air, do not remain in the dan‐
ger zone (catch basket) unless strictly necessary.
6. When cleaning the delivery line with compressed air, do not
clean towards the concrete pump hopper.
Putzmeister accepts no liability for damage caused by incorrect im‐

plementation of compressed air cleaning.
Prerequisites:
✓ You have connected a wash-out tower to the delivery line or instal‐
led a delivery line to a container.

Operation
Figure 50: Compressed air cleaning
Item Designation
1 Gate valve
2 Catch basket
3 “Wash-out tower” delivery line
1. Close the gate valve for the concrete pump.

⇒ The concrete flows into the connected wash-out tower or con‐
tainer.
2. Switch the pump to “Reverse pumping”.
3. Switch the pump off after one to two strokes.
⇒ The pressure in the delivery line is dumped.
4. Connect the riser to the “Wash-out tower” delivery line.
5. Position an empty truck mixer by the wash-out tower.
6. Extend the delivery line on the wash-out tower into the intake fun‐
nel on the truck mixer.
7. Fit a catch basket at the end of the delivery line.

Operation
⇒ You have prepared the “Wash-out tower” delivery line.
Figure 51: Placing wash-out sponges in the wash-out adaptor
Item Designation
1 Wash-out adaptor
2 Delivery line on the boom tip
3 Concrete
8. Place two wash-out sponges in the wash-out adaptor.

9. Remove the end hose from the boom tip.
10. Place one wash-out sponge in the delivery line on the boom tip.
11. Fit the wash-out adaptor on the delivery line on the boom tip.
Figure 52: Filling the wash-out adaptor with water
Item Designation
1 “Water” connection
2 Water
3 Pressure dump elbow
12. Fill the wash-out adaptor with water at the “Water” connection.
13. Close the “Water” connection.
14. Open the gate valve on the “Wash-out tower” delivery line.

Operation
Figure 53: Filling the wash-out adaptor with compressed air
Item Designation
1 “Compressed air” connection
2 Pressure gauge
15. Connect the compressed air supply to the “Compressed air” con‐
nection.
16. Open the “Compressed air” connection.
WARNING
Risk of blockage
1. Dump the pressure in the delivery line if the pressure gauge on
the wash-out adaptor indicates an increased air pressure.
2. Attempt to remove blockages by reverse pumping and then re‐
starting forward pumping.
3. If the blockage is not removed, dump the delivery line pressure
before removing the section of delivery line concerned.
17. Monitor the air pressure on the pressure gauge.

⇒ The sponge balls are caught by the catch basket.
18. Repeat the washing out process in the same sequence with a
larger quantity of water.
If there is a risk of freezing:
19. Completely empty the delivery line.
➙ You have cleaned the delivery line.

Operation
5.7.5 Cleaning the core pump
Prerequisites:
✓ You have familiarised yourself with the warning notices for clean‐
ing:
✓ You have cleaned the delivery line.
(Clean the delivery line P. 5 — 38)
✓ If your machine has a level control:
The level control is switched off.
This machine is equipped with an agitator safety cutout.

(Agitator safety cutout P. 3 — 11)
▶ When restarting, switch the concrete pump off first, and then back
on again.
5.7.5.1 Draining concrete residue
Figure 54: Lay the sheet down
1. Place the Putzmeister concrete residue sheet under the hopper.

Operation
2. Make sure that there is nobody underneath the hopper.

3. Open the cleaning flap on the hopper.
⇒ The concrete residue flows out of the hopper.
4. Switch the pump over to reverse pumping.
⇒ The concrete residue is pumped out of the delivery cylinders
and into the hopper, and thereby to the hopper opening.
Figure 55: Hoisting the concrete away
You may only hoist a maximum of 0.5 m3 of concrete (approx.

1200 kg) using the Putzmeister concrete residue sheet.
5. Hoist away the concrete in the concrete residue sheet.
5.7.5.2 Draining the water box
CAUTION
Risk of burning due to hot water in the water box
1. Exercise the necessary caution when working on the water box.
2. Allow the water to cool before carrying out maintenance work

Operation
1. Place a container underneath the water outlet point of the water

box.
2. Remove the lid.
3. Open the water outlet.
⇒ The water drains out.
4. Slowly move the delivery pistons until the water has drained com‐
pletely.
5. Check the condition of the water.
⇒ The water is clear or slightly cloudy.
There is a visible oil film on the water?

The drive cylinder seals are worn.
▶ Replace the drive cylinder seals.
The water is very cloudy and chalky white?

The delivery pistons may be worn.
1. Check whether there are grout deposits in the water box.

2. If necessary, replace the delivery pistons.
6. Dispose of the collected water.

5.7.5.3 Cleaning the hopper
Prerequisites:
▶ Clean the hopper.
5.7.5.4 Spraying out the delivery cylinder
Prerequisites:
✓ You have familiarised yourself with the warning notices for clean‐
ing:
✓ You have marked a water hose.
(Marking the water hose P. 5 — 36)

Operation
Figure 56: Spray out the transfer tube valve and delivery cylinder in cases where the
concrete pump is running backwards slowly
1. Open the hinged elbow.

2. Allow the concrete pump to pump in reverse with a low output.
3. Spray the transfer tube out carefully downwards from the hinged
elbow.
4. Slowly feed the hose in up to the marking .
Figure 57: Feed the water hose into the hydraulic diversion valve up to the mark
5. Hold the water hose inserted up to the marking in this position.

⇒ The delivery cylinders are rinsed out alternately.
⇒ Clear water will emerge once the delivery cylinders are
cleaned.
6. Rinse out the feeder container carefully with a water hose.

Operation
5.7.5.5 Checking the wear ring
Item Designation
1 Transfer tube
2 Thrust ring
3 Wear ring
4 Spectacle wear plate
▶ Check the gap between the transfer tube and the wear ring.
➙ The gap is 1.5–2 mm
➙ The wear ring has not reached its wear threshold.
The gap exceeds 2 mm?

1. Readjust the transfer tube.
2. Replace the wear ring if necessary.
5.7.5.6 Cleaning the gap between the transfer tube bearing and the transfer
tube
After each pumping operation, you must clean the transfer tube bear‐
ing thoroughly to prevent any concrete encrustation in the transfer
tube bearing.

Operation
6
5
Figure 58: Example illustration of cleaning the transfer tube bearing
Item Designation
1 S transfer tube
2 Transfer tube bearing
3 Square section seal ring
4 Areas that must be cleaned
5 Lubrication points
6 Hinged elbow
1. Open the hinged elbow.

2. Remove the square section seal ring.
3. Carefully spray out the surfaces to be cleaned of the transfer tube
bearing.
4. After cleaning, immediately grease the transfer tube bearing via
the lubrication points provided.

Operation
⇒ Grease visibly emerges from between the transfer tube and

transfer tube bearing.
5. Clean the square section seal ring.
6. Grease the square section seal ring.
7. Insert the square section seal ring.
8. Close the hinged elbow.
5.7.5.7 Close hinged elbow
2 3 2 4
Figure 59: Hinged elbow lock
Item Designation
1 Lettering “0” or milling
2 Retaining bolt for hinged elbow
3 Milling for recognizing the correct mounting position.
4 Hinged elbow
5 Wedge

Operation
Item Designation
6 Tie rod for retaining bolt
7 Spring pin
The retaining bolt (2) must be screwed onto the tie rod (6) as
shown in the figure above (lettering “0” or milling (1) upwards). On‐
ly in this way can the chock (5) be used for locking the hinged el‐
bow.
1. Check that the retaining bolt (2) is firmly seated.

2. Check the installation position of the retaining bolt (2).
3. Lock the hinged elbow (4) with the chock (5).
4. Secure the chock (5) with the spring pin (7).
5.7.6 Cleaning the remote control
Permitted auxiliary devices for cleaning the remote control:

● Clean cloth
● Brush (e.g. for LEDs)
● Cleaning agents:
● Non-caustic
● Non-abrasive
Prerequisites:
✓ The remote control is switched off.
▶ Gently clean the remote control by hand.
5.7.7 Cleaning other machine components
All machine components that have come into contact with concrete
must be thoroughly sprayed clean. Concrete that is not washed off
immediately can attack the paint, especially if aggressive concrete
additives have been used.
1. Spray the remaining machine components with water.

2. Empty the water tank if there is a risk of freezing.
3. Leave the water outlet open until refilling is completed.
4. Clean all seals and seal seats.

Operation
5. Grease the seals before replacing them.

6. Immediately after washing out, grease all bearing points in the
hopper area at the lubrication points provided.
⇒ Grease visibly emerges from the bearing points.
7. Grease all exposed piston rods.
8. Grease the interior surfaces of the delivery cylinder.
9. Grease the untreated surfaces of mechanical parts (race ring,
rollers, etc.).
10. Spray the metal components with an anticorrosion agent or a re‐
lease agent.
5.8 Storing the machine

When placing the machine in storage for more than four weeks, you
must carry out the following preservation measures to preserve its
value.
▶ Carry out these preservation measures approximately every three
months.
If required due to the climatic conditions to which the stored ma‐

chine is exposed, you must carry out these preservation measures
at shorter intervals.
5.8.1 Document the measures taken to preserve value
▶ Document the date that the machine is placed into storage and
the value preservation measures that are carried out.
5.8.2 General measures to preserve value
1. Protect the untreated surfaces (control blocks, pins, spring pins,

etc.) with a suitable preserving agent.
2. Grease the untreated surfaces of mechanical parts (rollers,
chains, etc.) with Vaseline.
3. Rectify any corrosion damage.
4. Completely fill all fuel tanks with fuel.
5. Close the fuel tanks.

Operation
5.8.3 General measures to preserve the value of the electrical system as‐
sembly
WARNING
Risk of explosion
▶ Make sure that the battery terminals are not short-circuited.
5.8.3.1 Measures for preserving the value of Deutz engines with an electronic
engine governor
NOTICE
Control unit with run-down time
Interrupting the run-down time will cause a fault in the control unit.
This fault is shown continuously in the display, which means that
you run the risk of overlooking other faults. Putzmeister will not ac‐
cept warranty claims for engine damage and operating errors that
result from a failure to switch off the engine according to the instruc‐
tions.
▶ Do not disconnect or switch off the battery until the run-down
time (approx. 20 seconds) has elapsed.
When you switch off the engine, you must follow the instructions be‐
low:
1. Only switch off the engine using the IGNITION-STARTER SWITCH.
2. Do not unplug the control unit plug when the power supply is
switched on (ignition on).
3. When carrying out maintenance work on the machine (e.g. elec‐
tric welding work), always disconnect all plug-in connections on
the control unit.
4. Disconnect the battery.

Operation
5.8.3.2 Measures to preserve the value of the electrical system assembly

(general)
Prerequisites:
✓ If your machine is equipped with a Deutz engine with electronic en‐
gine governor:
You have complied with the specifications for preserving the value.
(Measures for preserving the value of Deutz engines with an elec‐
tronic engine governor P. 5 — 60)
1. Disconnect the battery.

2. Check the battery's state of charge.
▶ Charge the battery if required.
3. Connect the central control unit (CCU) to a supply voltage at six-
monthly intervals.
4. Protect electrical components against moisture and corrosion.
5.8.4 General measures to preserve the value of the water assembly
1. Empty the water tank and the water lines.

2. Leave the drainage openings open.
3. Drain the water box.
4. Leave the drainage openings open. Close the water box cover.
5. Drain the high-pressure water pump.
5.8.5 General measures to preserve the value of the engine assembly
1. Check that the cooling water contains sufficient anti-freeze and

corrosion protection.
2. Cover any exhaust pipes that exit upwards.
3. Detach exhaust pipes from the turbocharger.
4. Close the fuel supply line to the engine.
5.8.6 General measures to preserve the value of the concrete pump as‐
sembly
1. Grease all exposed piston rods with Vaseline.

2. Grease the interior surfaces of the delivery cylinder with Vaseline.

Operation
5.8.7 General measures to preserve the value of the hopper assembly
1. Open and lock the hopper flap.

2. Close the spray guard.
3. Spray the hopper area with barrier agent.

Glossary
This chapter illustrates the control system symbols (icons for concrete
pumps) and explains the abbreviations and technical terms that are
used in Putzmeister Operating Instructions.
214490294_2021-12-20_en Operating Instructions B—1

B—2 Operating Instructions 214490294_2021-12-20_en
Glossary
1 Symbols for concrete pumps in accordance with

German Mechanical Engineering Association
Standard (VDMA -24119)
3701 3713 3725 5008 6012 7005
3702 3714 4001 6001 6013 7006
3703 3715 4002 6002 6014 7007
3704 3716 4003 6003 6015 7008
3705 3717 4004 6004 6016 7009
3706 3718 5001 6005 PM6017 7010
3707 3719 5002 6006 PM6018 7011
3708 3720 5003 6007 PM6019 7012
3709 3721 5004 6008 7001 8001
3710 3722 5005 6009 7002 8002
3711 3723 5006 6010 7003 8003
3712 3724 5007 6011 7004 8004
Figure 60: “General” symbols 1

Glossary
8005 10005 10017 12001 12013 12025
8006 10006 10018 12002 12014 12026
8007 10007 10019 12003 12015 12027
8008 10008 10020 12004 12016 12028
8009 10009 10021 12005 12017 12029
9001 10010 10022 12006 12018 12030
9002 10011 10023 12007 12019 12031
9003 10012 10024 12008 12020 12032
10001 10013 10025 12009 12021 12033
10002 10014 11001 12010 12022 12034
10003 10015 11002 12011 12023 12035
10004 10016 11003 12012 12024 12036

Glossary
12037 12043 12049 12055 13004 14003
12038 12044 12050 12056 PM13005 15001
12039 12045 12051 12057 PM13006 15002
12040 12046 12052 13001 PM13007 15003
12041 12047 12053 13002 14001
12042 12048 12054 13003 14002
Symbols key: General
Item Designation
3701 Delivery rate regulation using potentiometer
3702 Delivery rate regulation using toggle switch
3703 Increase delivery rate
3704 Reduce delivery rate
3705 Reverse pumping
3706 Pumping On
3707 Pumping Off
3708 Pumping On - Off
3709 Pumping stand by
3710 Pumping in general
3711 Rotor pump in general
3712 Delivery rate flow meter (pump flow meter)
3713 Full delivery rate
3714 Half delivery rate
3715 High pressure pump
3716 Pump control system

Glossary
Item Designation
3717 Changeover
3718 Stroke pulse for change-over
3719 Stroke correction
3720 Change-over delay
3721 Screw conveyor 1 anticlockwise rotation
3722 Screw conveyor 1 clockwise rotation
3723 Screw conveyor 2 anticlockwise rotation
3724 Screw conveyor 2 clockwise rotation
3725 Screw conveyor
4001 Centralised grease lubrication, manual
4002 Centralised grease lubrication, automatic
4003 Centralised oil lubrication, manual
4004 Centralised oil lubrication, automatic
5001 Agitator, hopper
5002 Agitator clockwise rotation
5003 Agitator anticlockwise rotation
5004 Hopper empty
5005 Hopper full
5006 Agitator cut-out
5007 Hopper level control
5008 High-pressure agitator
6001 Hydraulic fluid excess temperature
6002 Radiator
6003 Radiator 1
6004 Radiator 2
6005 Fill the accumulator
6006 Dump accumulator pressure
6007 Hydraulic cylinder blockage
6008 High pressure hydraulic system
6009 Hydraulic fluid low
6010 Hydraulic fluid
6011 Air
6012 High pressure
6013 Accumulator pressure

Glossary
Item Designation
6014 Filter element
6015 Rod side
6016 Piston side
6017 Hydraulic fluid filter water level stop (PM symbol)
6018 Hydraulic fluid filter water level warning (PM symbol)
6019 Hydraulic fluid filter contamination warning (PM symbol)
7001 Spotlights
7002 Lighting
7003 Control cabinet lighting
7004 Toolbox lighting
7005 Rear light
7006 Spirit level lighting
7007 Flashing beacon
7008 Acknowledge flashing beacon
7009 Acknowledge flashing beacon
7010 Side marker light container
7011 Lighting mast
7012 Diagnostics lamp
8001 Machine diagnostics connector
8002 Read-out data
8003 Read-in data
8004 Read-in minimum value
8005 Reset memory contents (save)
8006 Cancel memory contents (clear)
8007 Start
8008 Read-in maximum value
8009 Menu
9001 Control cabinet
9002 Diagnosis plug socket
9003 Teleservice
10001 Diesel engine On
10002 Diesel engine Off
10003 Engine oil excess temperature
10004 Cooling water excess temperature

Glossary
Item Designation
10005 Acknowledge cooling water excess temperature
10006 Engine oil pressure
10007 V-belt failure
10008 Increase speed, reduce speed
10009 Speed
10010 Speed sensor
10011 Increase speed
10012 Reduce speed
10013 Engine air filter
10014 Electric motor in general
10015 Silent
10016 Reduced fuel consumption
10017 Tank monitoring
10018 Coolant level
10019 Diesel engine control
10020 Starter
10021 Manual throttle lever
10022 Start-up relief (soft start)
10023 Diesel supply On
10024 Diesel supply On
10025 Fuel filter draining
11001 Radio remote control
11002 General remote control
11003 Plug in remote control
12001 Horn
12002 General fault
12003 Acknowledge
12004 Battery
12005 Battery charging device
12006 EMERGENCY STOP actuated
12007 Acknowledge EMERGENCY STOP
12008 Stop
12009 Test run
12010 Vibrator On

Glossary
Item Designation
12011 Vibrator Off
12012 Vibrator
12013 Potentiometer
12014 Off - On
12015 On
12016 Off
12017 Fast (e.g. acceleration)
12018 Normal (e.g. acceleration)
12019 Compressor
12020 Compressor on - off
12021 Motor vehicle fuse
12022 Cable drum
12023 Operating hours meter
12024 Operating position
12025 Electrical power
12026 Automatic/manual
12027 Automatic operation
12028 Close shut-off device
12029 Open shut-off device
12030 Water tank heating
12031 Cleaning
12032 Levelling control in general
12033 Excess pressure
12034 Fuse test
12035 Timer relay
12036 Right-hand side
12037 Left-hand side
12038 Concrete brake
12039 Buzzer
12040 Container
12041 Position at the machine
12042 Lock
12043 2nd level
12044 Circuit 1

Glossary
Item Designation
12045 Circuit 2
12046 Circuits 1+2
12047 High-pressure limit
12048 Flap/closure closed
12049 Flap/closure open
12050 Generator
12051 Boom on cradle
12052 Manual operation
12053 Electrical levelling
12054 See Operating Instructions
12055 Wear measurement
12056 Water
12057 Overhead roll-and-fold boom
13001 Power takeoff
13002 Truck in general
13003 Plan view
13004 Brake in general
13005 Drive (PM symbol)
13006 Lift axle raised (PM symbol)
13007 Lift axle not raised (PM symbol)
14001 Mixer in general
14002 Empty mixer
14003 Activate mixer
15001 Water glass dosing pump
15002 Flushing water pump
15003 Highpressure water pump
B — 10 Operating Instructions 214490294_2021-12-20_en

Glossary
2 Abbreviations and technical terms
A
Accumulator charge pressure The accumulator charge pressure
is the pressure at which the accu‐
mulator charging pump fills the ac‐
cumulator with hydraulic fluid.
Accumulator pressure (Accumulator charge pressure

P. B — 11)
ADR (Speed of rotation regulation

P. B — 17)
Agitator safety cutout The agitator safety cutout (RSA)

stops hazardous concrete pump
movements when the grille is
opened.
(Grille P. B — 14)
APP (Automatic Piston Pull

P. B — 11)
Automatic Piston Pull A ball valve is installed in the drive

cylinder. When the ball cock is
closed, you can pull the delivery
piston out of the delivery cylinder
to replace it.
B
Blockage Blockage in the delivery line:
214490294_2021-12-20_en Operating Instructions B — 11

Glossary
The concrete behind the blockage

cannot continue to flow. The block‐
age is caused, for example , by
grain getting wedged or being too
coarse, etc.
C
Changeover Reversal of the delivery pistons’
direction in the middle of the
stroke movement:
The (Transfer tube P. B — 18)

switches.
The concrete is still pumped with‐

out interruption.
Change-over delay throttle The change-over delay throttle is a

(UVD) hydraulic component that delays
the switchover of the transfer tube.
(Transfer tube P. B — 18)
Check book The check book is part of the doc‐

umentation accompanying the ma‐
chine:
Checklist with confirmation of the

legally required checks for con‐
crete pumps and placing booms
Corner bearing load The corner bearing load is the

force which the machine exerts on
each corner of its tilting edge.

Glossary
(Tilting edge P. B — 18)
D
dB Decibels: Unit of measurement for
the (Sound power level
P. B — 17)
dB (A) Decibels (A): Unit of measurement

for the (Sound pressure level
P. B — 17)
E
EDC (Electronic Diesel Control
P. B — 13)
Electronic Diesel Control Automatic vehicle-specific control

of fuel consumption
EOC (Ergonic Output Control

P. B — 13)
EPS (Ergonic Pump System

P. B — 14)
Ergonic ® Registered brand name for all

Putzmeister components which
control concrete pumps and plac‐
ing booms.
Ergonic Output Control Microprocessor supported system

for economic operation of the con‐
crete pump. For the output set by
the machine operator, only the
minimum required engine speed
will be set automatically.

Glossary
Ergonic Pump System Microprocessor supported system

for controlling and regulating the
concrete pump. Among other func‐
tions, EPS allows you to restrict
the delivery pressure and output.
F
Free-Flow Hydraulics The Free-Flow Hydraulics system
is a type of concrete pump drive
that switches the fluid flow from
the main pump directly to the drive
cylinders, i.e fluid flows freely with‐
out interposing valves.
Fully hydraulic control system The fully hydraulic control system

(VHS) controls the concrete pump by
switching the fluid flow from the
main pump to the drive cylinder by
means of valves (closed, non-pre‐
stressed hydraulic circuit).
Functional fluids Hydraulic fluid, fuel, brake fluid,

battery acid etc.
G
Grille The grille is the cover grille for the
hopper.

Glossary
The grille has two functions:

● It only allows grain up to a par‐
ticular size to pass through
● It stops people being able to
reach into the hopper
L
Level control Level control controls the amount
of concrete in the hopper during
pumping operations using a fill-lev‐
el sensor.
M
Machine card The machine card is part of the
documentation accompanying the
machine:
● List of the machine components
● Circuit diagram information
Maintenance card A maintenance card describes

measures and their sequence for
maintaining the machine and for
replacing parts and wear parts.
O
Operating equipment Battery, filters
P
PEDOC Putzmeister Electronic Documen‐
tation
(Putzmeister Electronic Documen‐

tation P. B — 16)

Glossary
Piston end-of-travel positioning Piston end-of-travel positioning

(KEP) is a function for replacing
the delivery pistons. A ball valve
(KEP shut-off valve) is installed in
the drive cylinder. If the ball valve
is closed, it is possible to lock the
drive cylinders in the end position.
Piston side
Precharge pressure The precharge pressure is the

pressure of the gas in the accumu‐
lator bladder when there is no hy‐
draulic system fluid pressure.
Putzmeister Electronic Docu‐ Documentation accompanying the

mentation machine on CDROM
R
Reversal The concrete is sucked back from
the delivery line into the hopper.
Rod side
RSA (Agitator safety cutout P. B — 11)
S
Service operation Use the “Pumping operation-Serv‐
ice operation” toggle switch on the
control cabinet to switch over be‐
tween the concrete pump and the
compressor. You can switch on

Glossary
the compressor, rather than the

pump, at the remote control if you
switch the switch to the ““compres‐
sor”” position.
Sound power level The sound power level is a relative

measurement used in acoustics to
indicate the noise emissions from
a noise source [dB].
An imaginary sphere of defined di‐

ameter is centred on the machine.
The sound pressure level is meas‐
ured at several measuring points
on this sphere. The sound power
level is the product of the sound
pressure level and the surface of
the imaginary sphere.
Sound pressure level The sound pressure level is a log‐

arithmic measurement for the rela‐
tive loudness of the sound
[dB (A)].
The sound produced by the ma‐

chine is measured at a fixed dis‐
tance and height at several meas‐
uring points. The average value of
the values measured is the sound
pressure level.
Speed of rotation regulation The ADR function regulates the

mixer drum speed while the truck
is being driven.
Squeeze valve The squeeze valve is a component

on the end hose which closes the
delivery line when the pump is
stopped.

Glossary
Stroke correction The stroke is corrected automati‐

cally by the addition or removal of
hydraulic fluid through bores in the
drive cylinders. Stroke correction
means that the delivery pistons
can achieve their maximum stroke
length. Without stroke correction,
the delivery piston would not al‐
ways reach its end position.
Support foot A support foot supports the ma‐

chine and transfers a corner bear‐
ing load to the supporting ground.
(Corner bearing load P. B — 12)
T
Teach-in Specialist word for storing in mem‐
ory
Test reading The measurement record is part of

the documentation accompanying
the machine:
List of the machine setting values
Tilting edge The tilting edge surrounds the ma‐

chine. The machine topples over
as soon as its centre of mass is
outside the tilting edge.
Transfer tube The transfer tube is a component

which is swung between the two
delivery cylinders in the hopper. It
is the connection between the de‐
livery cylinder and the delivery
line.

Glossary
Triggering The magnetic switches are trig‐

gered, i.e. when an object is
brought near, they switch without
any contact being made.

Index
Index
In this chapter, you will find the most important keywords and the number(s) of the page(s) on which they
appear. This index of key words is in alphabetical order.
A Checking the EMERGENCY STOP function P. 3 — 10,

5 — 10
Abbreviations and technical terms P. 6 — 11
Checking the functions P. 5 — 9
Accessories and attachments P. 2 — 15
Checking the hydraulic fluid filters P. 5 — 14
Additional cooling P. 5 — 29
Checking the machine for damage P. 5 — 3
Additional lubrication procedure P. 3 — 62
Checking the pressure filter P. 5 — 15
After Sales Service personnel P. 2 — 5
Checking the pump functions P. 5 — 13
Agitator P. 3 — 53
Checking the setup site P. 4 — 5
Agitator safety cutout P. 3 — 11
Checking the stroke length P. 5 — 14
Arm assembly P. 2 — 3
Checking the stroke time P. 5 — 14
B Checking the switchover P. 5 — 13
Base structure P. 2 — 3 Checking the wear ring P. 5 — 55
Before working with the machine P. 2 — 21 Check the contamination indicator P. 5 — 15
Blockage P. 5 — 26 Check wear P. 3 — 16
Breaks in pumping P. 5 — 25 Cleaning P. 2 — 42, 5 — 30
Cleaning agents P. 2 — 43
C
Cleaning other machine components P. 5 — 58
Cable remote control P. 3 — 45
Cleaning preparations P. 5 — 32
Centralised lubrication system P. 3 — 60
Cleaning the core pump P. 5 — 51
Changeover P. 3 — 49
Cleaning the gap between the transfer tube bearing and
Changes to the machine P. 2 — 15
the transfer tube P. 5 — 55
Check function P. 3 — 8
Cleaning the hopper P. 5 — 53
Checking functional fluids P. 5 — 6
Cleaning the remote control P. 5 — 58
Checking that the machine is ready for operation
Cleaning with compressed air P. 2 — 44, 5 — 46
P. 2 — 21
Cleaning with pressurised water P. 5 — 44
Checking the agitator safety cutout P. 3 — 14, 5 — 11
Clean the delivery line P. 5 — 38
Checking the condition of the machine P. 5 — 25
Clearances P. 2 — 22
214490294_2021-12-20_en Operating Instructions C—1

Index
Clearance to delivery lines P. 2 — 39 Display P. 3 — 28
Climbing the placing boom P. 2 — 15 Disposing of concrete residue P. 5 — 38
Close hinged elbow P. 5 — 57 Document the measures taken to preserve value

P. 5 — 59
Colour definition – LEDs in the button P. 3 — 24
Draining concrete residue P. 5 — 51
Concrete pump P. 2 — 3
Draining the hydraulic fluid reservoir P. 5 — 5
Concreting in cold weather P. 2 — 37
Draining the water box P. 3 — 52, 5 — 52
Connecting an auxiliary pump P. 5 — 45
Driving P. 2 — 31, 4 — 5
Connecting drills P. 2 — 36
Dumping the pressure in the delivery line P. 5 — 44
Connections P. 3 — 25
Constant observation of the machine P. 2 — 42

E
Continuation delivery lines P. 2 — 39
Earthing in the event of electrostatic charging P. 2 — 25
Control cabinet P. 3 — 25
Earthing on construction sites with special installations
Cooling P. 5 — 28 P. 2 — 25
“Core pump” menu P. 3 — 34 Electromagnetic compatibility (EMC) P. 3 — 20
Core pump P. 3 — 45, 3 — 48 EMERGENCY STOP function P. 3 — 8
Core pump operating panel P. 3 — 26 EMERGENCY STOP hand signal P. 5 — 17
Corner bearing loads P. 2 — 29 End hose P. 2 — 4, 2 — 10, 2 — 35
Entire machine P. 3 — 42
D
Exclusion of liability P. 2 — 16
Damping valve P. 5 — 21
Exhaust after treatment P. 3 — 21
Danger due to high voltage P. 2 — 22
Extending the placing boom and end hose P. 2 — 13
Dangers during pumping P. 5 — 20
Extending the reach P. 2 — 13
Danger zone P. 2 — 9
Extend supports P. 4 — 11
Deactivating the agitator safety cutout P. 3 — 13, 5 — 9
Deactivating the EMERGENCY STOP P. 3 — 9, 5 — 8 F

Definition of terms P. 2 — 3 Filling the lubricant reservoir P. 3 — 61
DEF tank P. 3 — 29 Filling the lubricant reservoir using a grease gun

P. 3 — 62
Delivery line systems P. 2 — 4, 2 — 10, 2 — 37
Filling the water box P. 3 — 51, 5 — 19
Designated use P. 2 — 10
Folding down the support foot P. 4 — 14
Devices for shutting off, diverting and cleaning
P. 2 — 40 Foreword P. 1 — 3
Discharge voltage pattern P. 2 — 22
C—2 Operating Instructions 214490294_2021-12-20_en

Index
Function P. 3 — 8, 3 — 12, 3 — 22, 3 — 48, 3 — 50, Highvoltage warning devices P. 2 — 24

3 — 53, 3 — 56, 3 — 60
Hopper P. 2 — 10
Function bar P. 3 — 32
Hoseman P. 2 — 4
G I
General P. 2 — 42
Icons and symbols P. 1 — 4
General conditions for using the machine P. 3 — 17
Impermissible end hose P. 2 — 14
General measures to preserve the value of the concrete
Impermissible working area P. 2 — 9, 2 — 14
pump assembly P. 5 — 61
Improper use P. 2 — 12
General measures to preserve the value of the electrical
system assembly P. 5 — 60 Indicator lights P. 3 — 57
General measures to preserve the value of the engine “Inputs and outputs” menu P. 3 — 39
assembly P. 5 — 61 Inserting the wash-out sponge P. 5 — 45
General measures to preserve the value of the hopper Insert the wash-out sponge P. 5 — 41
assembly P. 5 — 62
Inspection intervals for retesting P. 2 — 11
General measures to preserve the value of the water
assembly P. 5 — 61
L
General measures to preserve value P. 5 — 59
Layout of warning notices P. 1 — 5
General technical description P. 3 — 1
Leak tightness and blockages P. 2 — 38
Glossary P. 6 — 1
Lifting loads P. 2 — 13
Grille P. 3 — 16
Lifting machines and components P. 2 — 26
Guide to the Operating Instructions P. 1 — 1
Loading P. 2 — 32, 4 — 3
Guiding the end hose ergonomically P. 2 — 36
Loading and transporting P. 2 — 26
Lowering the forward support foot P. 4 — 15

H
Lowering the rear support feet P. 4 — 12
Hand signal for increasing output/start of delivery
P. 5 — 18
M
Hand signal for reducing output P. 5 — 18
Machine P. 2 — 3, 2 — 10
Hand signal for reverse pumping P. 5 — 19
Machine Cockpit P. 3 — 21
Hand signal for stopping P. 5 — 17
Machine data P. 3 — 19
Hand signal for stopping the pump P. 5 — 19
Machine operator P. 2 — 4
Hand signals for pumping operations P. 5 — 16
Machine rating plate P. 3 — 19
Highpressure delivery P. 2 — 15
Magnetic switch P. 5 — 13
High-voltage lines P. 2 — 22

Index
Magnetic switch connector P. 3 — 58 “Operating data” menu P. 3 — 41
Magnetic switch distributor casing P. 3 — 56 Operating elements P. 3 — 25
Main menu P. 3 — 30 Operating Instructions P. 2 — 17
Maintaining the centralised lubrication system Operating Instructions, operating procedures and other
P. 3 — 61 regulations P. 2 — 17
Maintenance P. 2 — 5 Operating procedures P. 2 — 18
Manufacturer P. 2 — 4 Operating temperature P. 3 — 18
Marking the water hose P. 5 — 36 Operating the agitator P. 3 — 54, 5 — 22
Measures for preserving the value of Deutz engines Operation P. 5 — 1

with an electronic engine governor P. 5 — 60
Operator P. 2 — 4
Measures to preserve the value of the electrical system
Other regulations P. 2 — 19
assembly (general) P. 5 — 61
Overheating P. 5 — 27
Menu content P. 3 — 31
Overview P. 3 — 5
Messages P. 3 — 42
Overview of the cleaning methods P. 5 — 38
Minimum clearance from pits P. 4 — 6
Overviews P. 3 — 3
Mixing together P. 5 — 22
Mobile machines P. 2 — 6, 2 — 27 P
“Motor” menu P. 3 — 37 Personal protective equipment P. 2 — 19
Motor P. 3 — 43 Personnel P. 2 — 16
Motor fault codes P. 3 — 39 Place of work P. 2 — 8, 2 — 40
Motor overload P. 5 — 27 Place of work, working area, danger zone P. 2 — 6
Moving machine components and hot surfaces Place of work – hoseman P. 2 — 8
P. 2 — 41
Place of work – machine operator P. 2 — 8
N Place of work – truck mixer driver P. 2 — 8
Navigation bar P. 3 — 30 Placing boom P. 2 — 3, 2 — 9
Notes on correct pumping P. 5 — 21 Placing booms P. 2 — 33
Plates P. 3 — 8
O Positions of the EMERGENCY STOP buttons P. 3 — 9
Observe the notes on cleaning P. 5 — 32
Post-cleaning procedure P. 2 — 46
Opening delivery lines P. 2 — 39
Pre-fitting the catch basket P. 5 — 33
Operating altitude P. 3 — 18
Preparing cement bags P. 5 — 36
Operating data P. 3 — 20
Procedure in storms P. 2 — 36

Index
Procedure in the event of a flash over P. 2 — 24 Safety regulations P. 2 — 1
Protection against water P. 2 — 46 Safety-related parts (SRPs) P. 3 — 6
Pumping P. 5 — 20 Securing delivery lines P. 2 — 38
Pumping operations P. 2 — 40 Securing the delivery lines P. 2 — 39
Pumping water P. 5 — 45 Service life P. 3 — 17
Putzmeister Connected Services P. 3 — 21 Setting up the machine P. 4 — 11
Setup site P. 2 — 25, 2 — 27

Q
Signaller and other auxiliary personnel P. 2 — 5
Qualifications P. 2 — 17
Significance of the LEDs P. 3 — 58
Qualified personnel P. 2 — 5
Site of use P. 3 — 18
R Software P. 3 — 29
Rectify any faults P. 5 — 26 Sound pressure level P. 3 — 20
Regeneration P. 3 — 22 Sound pressure level/sound power level P. 3 — 20
Remote control P. 2 — 41 Spraying out the delivery cylinder P. 5 — 53
Remote Service P. 3 — 21 Starting regeneration P. 3 — 23
Removing obstacles P. 2 — 13 Starting the pumping process P. 5 — 25
Rendering the machine ready for operation P. 2 — 21 Starting to pump P. 5 — 23
Requirements P. 2 — 16 Starting up P. 5 — 3
Responsibility of the machine operator P. 2 — 17 Stationary delivery line P. 5 — 40
Restarting after overheating P. 5 — 29 Stationary machines P. 2 — 6, 2 — 25
Retesting (safety inspection) P. 2 — 11 Stationary placing booms P. 2 — 26
Retracting the supports P. 4 — 16 Storing the machine P. 5 — 59
Reversal P. 3 — 49 Structure P. 3 — 12, 3 — 45, 3 — 48, 3 — 50, 3 — 53,

3 — 56, 3 — 60
Reverse pumping the concrete P. 5 — 41
Subject expert P. 2 — 5
S Sucking in air P. 5 — 20
Safe clearance from pits P. 4 — 8 Suction cleaning P. 5 — 40
Safely using the remote control P. 3 — 47 Suitable delivery lines P. 2 — 37
Safety P. 2 — 40 Supporting ground P. 2 — 28, 4 — 9
Safety components P. 3 — 6 Supporting the machine P. 4 — 5
Safety equipment P. 3 — 5 Support legs and support feet P. 2 — 9

Index
Supports P. 2 — 29 Water box P. 3 — 50
Support structure P. 4 — 10 Working area P. 2 — 8
Switching on the machine P. 5 — 7
Symbols P. 5 — 39
Symbols for concrete pumps in accordance with Ger‐

man Mechanical Engineering Association Standard
(VDMA -24119) P. 6 — 3
Symbols key: General P. 6 — 5
T
T delivery pipe with wash-out port P. 5 — 33
Test run P. 5 — 3
Towing P. 2 — 32
Tracking the wash-out sponge P. 5 — 42
Transport, support and connection P. 4 — 1
Transporting P. 4 — 3
Transporting concrete residue with a sheet P. 5 — 37
Transporting goods P. 2 — 12
Trapping the wash-out sponge P. 5 — 43
Truck mixer P. 2 — 4, 2 — 42
Truck mixer driver P. 2 — 5
U
Unfold placing boom P. 2 — 33
“User settings” menu P. 3 — 33
Using concrete residue P. 5 — 37
V
Vibrator P. 3 — 55
W
Warming up the hydraulic fluid P. 5 — 8
Wash-out adaptor P. 5 — 34

Service Instructions
for machine operator and maintenance staff
always keep by the machine
Translation of the original instructions
Stationary concrete pump BSA 1005 D4F
Machine no. 2106T5571

214490294
2021-12-20
The paper on which this document is printed is 100% chlorine-free © Putzmeister Concrete Pumps GmbH 2021
Putzmeister Concrete Pumps GmbH +49−7127−599−0 pmw@pmw.de
land Max−Eyth−Straße10
PM D− 72631 Aichtal +49−7127−599−520 www.putzmeister.de
España Putzmeister Ibérica S.A. +34−91−428 81 00 recepcion@putzmeister.es

PME Camino de Hormigueras 173
Pol. Ind. Vallecas +34−91−428 81 43 www.putzmeister.es
E− 28031 Madrid
France Putzmeister France +33−164 64 39 39 Infopmf@putzmeister.fr
PMF 3, rue Paul Henri Spaak
ZAE Jean Monnet +33−164 64 39 29 www.putzmeister.fr
77240 Vert Saint Denis
Great Putzmeister Limited +44−1246−2642 00 info@putzmeister.co.uk
Britain Carrwood Road
PMUK GB−Chesterfield +44−1246−26 00 77 www.putzmeister.co.uk
Derbyshire S41 9QB
Türkiye Putzmeister Makine Sanayi ve Tic. A. +90−282−735−1000 pm@putzmeister.com.tr
PTR G.O. Pa a Mah.
Nam k Kemal Bulvar No: 6 +90−282−738−1001 www.putzmeister.com.tr
59500 Çerkezköy / TEK
USA Putzmeister America +1−262−886−3200 pmr@putzam.com
PMA 1733 90th Street
Sturtevant, WI 53177 USA +1−262−886−3212 www.putzmeister.com
South Putzmeister S.A. (Pty) Ltd. +27−11−794−37 90 pmsa@icon.co.za

Africa Cnr. Braam & Citrus St. Honeydew
PMSA P.O.Box 5146 ZA 2118 Cresta +27−11−794−41 19 www.putzmeister.co.za
South Africa
India Putzmeister Concrete Machines Pvt Ltd info@pmw.co.in
PCM Plot No. N4, Phase IV
Verna Industrial Estate, Verna Salcete www.pmw.co.in
Goa−403722
Japan Putzmeister Japan Co. Ltd. +81-476-36-8907 info@putzmeister.jp

PMJ
7-4 Misawa, Tomisato-shi +81-476-36-8908 www.putzmeister.de/jp
Chiba 286-0225, Japan
Korea Putzmeister Korea Co. Ltd. +82−31−433−4541 putzmstr@chollian.net

PMK 59 Huimanggongwon-ro,Chungwang−Dong
Shihwa Ind. complex 2 MA 707-1HO, +82−31−498−7230 www.putzmeister.co.Kr
Shihung−city Kyunggi−Do, Korea
Russland OOO +7−495−775−22−37 info@putzmeister.ru
PMR Urgumskaja Straße 4, Geb. 31
129343 Moskau, Russia +7−495−775−22−34 www.putzmeister.ru
en Translation of the original instructions
ar ‫ترجمة دليل التشغيل الأصلي‬
bg Превод на оригиналното „Ръководство за работа“
cs Překlad originálního návodu k obsluze
da Oversættelse af den originale driftsvejledning
de Übersetzung der Originalbetriebsanleitung
el Μετάφραση του πρωτότυπου των οδηγιών λειτουργίας
es Traducción del manual de instrucciones original
et Originaalkasutusjuhendi tõlge
fi Alkuperäisen käyttöohjeen käännös
fr Traduction de la notice originale
hr Prijevod originalnog priručnika za rad
hu Az eredeti üzemeltetési utasítás fordítása
it Traduzione delle istruzioni per l'uso originali
ja 取扱説明書原本の翻訳
lt Naudojimo instrukcijos originalo vertimas
lv Oriģinālās lietošanas instrukcijas tulkojums
nl Vertaling van de originele handleiding
no Oversettelse av original bruksanvisning
pl Tłumaczenie oryginalnej instrukcji eksploatacji
pt Tradução das Instruções de funcionamento originais
ro Traducere a instrucţiunilor de funcţionare originale
ru Перевод оригинальной инструкции по эксплуатации
sk Preklad originálneho návodu na obsluhu
sl Prevod originalnih navodil za uporabo
sr Prevod originalnog uputstva za upotrebu
sv Översättning av instruktionsbok i originalutförande
tr Orijinal kullanım kılavuzunun tercümesi
zh 原始操作说明翻译
214490294_2021-12-20_en Service Instructions

Service Instructions 214490294_2021-12-20_en
2.
3.
...
Table of contents
1 Guide to the Service Instructions ............................................ 1—1

1.1 Foreword ......................................................................................................................... 1 —3
1.2 Icons and symbols .......................................................................................................... 1 —4

1.2.1 Layout of warning notices ............................................................................................... 1—5
2 Safety regulations ................................................................... 2—1

2.1 Basic principle ................................................................................................................. 2 —3
2.1.1 Exclusion of liability ......................................................................................................... 2—3
2.2 Requirements for special work ........................................................................................ 2 —3
2.3 Welding ........................................................................................................................... 2 —4
2.4 Working on the placing boom .......................................................................................... 2 —5
2.5 Safetyrelevant components ............................................................................................. 2 —6
2.6 Software .......................................................................................................................... 2 —6
2.7 Protective and safety equipment ..................................................................................... 2 —6
2.8 Electrical power ............................................................................................................... 2 —7

2.8.1 General ........................................................................................................................... 2—7
2.8.2 Electrical components ..................................................................................................... 2—8
2.8.3 Power at the construction site ......................................................................................... 2—8
2.9 Hydraulic systems ........................................................................................................... 2 —8

2.9.1 General ........................................................................................................................... 2—8
2.9.2 Replacing hydraulic hoses .............................................................................................. 2 — 10
2.10 Noise emissions .............................................................................................................. 2 — 10
2.11 Exhaust fumes ................................................................................................................ 2 — 10
2.12 Functional fluids .............................................................................................................. 2 — 11
2.13 Disposal of the machine .................................................................................................. 2 — 12
3 Special operating modes ........................................................ 3—1

3.1 Recovery with onboard equipment .................................................................................. 3 —3
3.1.1 Preparing for recovery ..................................................................................................... 3—3
3.1.2 Setting up the pump control system ................................................................................ 3—4
3.1.3 Emergency operation of the core pump .......................................................................... 3—5
214490294_2021-12-20_en Service Instructions A—1

2.
3.
...
4 Maintenance ........................................................................... 4—1

4.1 Maintenance intervals ..................................................................................................... 4 —3
4.2 Residual risks during maintenance, inspection and repair work ..................................... 4 —5
4.2.1 Personal protective equipment ........................................................................................ 4—5
4.2.2 Personnel requirements .................................................................................................. 4—5
4.2.3 Auxiliary devices ............................................................................................................. 4—5
4.2.4 Residual risks .................................................................................................................. 4—6
4.3 Specifications for bolted connections .............................................................................. 4 —8
4.4 General tightening torques .............................................................................................. 4 —8

4.4.1 Set screws and nuts ........................................................................................................ 4—9
4.4.2 Fitting threaded unions .................................................................................................... 4—9
4.4.3 Reassembly of WALFORMplus threaded unions ............................................................ 4 — 10
4.5 Functional fluids .............................................................................................................. 4 — 13

4.5.1 Hydraulic fluids ................................................................................................................ 4 — 13
4.5.2 Lubricant analysis ........................................................................................................... 4 — 17
4.5.3 Storage of lubricants ....................................................................................................... 4 — 17
4.5.4 Lubricant recommendation .............................................................................................. 4 — 17
4.6 Maintenance work ........................................................................................................... 4 — 19

4.6.1 Carrying out visual checks .............................................................................................. 4 — 19
4.6.2 Hydraulic system ............................................................................................................. 4 — 20
4.6.3 Core pump ...................................................................................................................... 4 — 32
4.6.4 Delivery line ..................................................................................................................... 4 — 102
Index ........................................................................................ C —1
A—2 Service Instructions 214490294_2021-12-20_en

1 Guide to the Service Instructions
In this chapter you will find notes and information that will help you
use these Service Instructions. If you have any queries, please
write to us in confidence at the address given below, or contact the
relevant branch or works agency.
Putzmeister Concrete Pumps
Abteilung Kundendienst
Max-Eyth-Straße 10
72631 Aichtal, Germany
Telephone: +49 (0) 7127 599-0
Fax: +49 (0) 7127 599-520
E-mail: services@pmw.de
You can contact your responsible branch or works agency by calling

the following service hotline.
Service hotline tel.: +49 (0) 1805 / 30 18 30
If you make a call with a mobile phone from the D1 or D2 network,

you will be put through to a service advisor in Aichtal who either as‐
sist you directly or specify the appropriate contact partner.
214490294_2021-12-20_en Service Instructions 1—1

1—2 Service Instructions 214490294_2021-12-20_en
Guide to the Service Instructions
1.1 Foreword
The Service Instructions contain important information about the
maintenance of the machine. 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 Service Instructions must be supplemented by the relevant na‐

tional rules and regulations for accident prevention and environmental
protection.
The Service Instructions must always be available wherever the ma‐

chine is in use.
These Service Instructions must be read and applied by any person

in charge of carrying out work with and on the machine, e.g.
● Operation, including setting up, fault rectification in the course of
work, removal of production waste, maintenance and disposal of
fuels and auxiliary materials,
● Maintenance (servicing, inspection, repair) and/or
● Transport.
In addition to the Service Instructions and mandatory rules and regu‐

lations for accident prevention in the country and place of use of the
machine, the generally recognised rules of technology for safe and
proper working must be observed.
Should you have any questions after studying the Service Instruc‐
tions, the branch or agency serving you, or the Aichtal Works, will be
happy to provide you with 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 num‐
ber.
These Service Instructions describe the vehicle superstructure only.

The Operating Instructions issued by the vehicle manufacturer apply
for the vehicle itself.
For the purpose of continuous improvement, changes are made at

certain times, meaning that these changes may in some circumstan‐
ces not yet have been taken into account by the time these Service
Instructions are sent to print.
In the event of any amendment, the copy of the Service Instructions

intended for the machine will be replaced in full.

The reproduction, distribution and utilisation of this document as well

as the communication of its contents to others without explicit authori‐
sation is prohibited. Offenders will be held liable for the payment of
damages. All rights reserved in the event of the grant of a patent, utili‐
ty model or design.
© Putzmeister Concrete Pumps GmbH 1994
1.2 Icons and symbols

The following icons and symbols are used:
designation
▶ Individual instruction or alternative step
1. 2. 3. Instructions to be carried out as described in the
specified sequence.
⇒ Intermediate result of multiple steps.
➙ End result of an individual instruction or of multi‐
ple steps.
● Bullet point list – Key words or short sentences
that provide comprehensive information. This in‐
cludes the various options available, enumera‐
tions, lists of components, etc.
Operating ele‐ Operating elements are written in small capitals to
ment make it immediately clear which operating ele‐
ment should be used. The designation is only
written in small capitals in continuous text and in
instructions. Tables and headings are not inclu‐
ded.
Link/cross ref‐ A link/cross reference to related topics. Cross ref‐
erence: erence with page number and heading. If the
(Icons and cross reference is displayed digitally, it acts as a
symbols direct link to a related topic area.
P. 1 — 4)
Fault rectification – Instructions to be carried out
in accordance with fault messages.

designation
View additional steps. For example, “Contact a
qualified electrician”.
✓ The requirements or tools outlined below must be
met or available.
Tests or inspections have been passed.
This indicates a tip, helpful note or additional in‐
formation regarding machine maintenance, envi‐
ronmental protection, etc.
1.2.1 Layout of warning notices
WARNING
Type and cause of risk
Consequences of not observing the risk.
▶ What to do in order to provide a remedy or avoid the risk.
Signal words
The signal word is chosen in accordance with the ANSI Z535.6:2011

safety standard.
The following signal words are used:
DANGER
rious injuries and/or death may occur. Highest level of risk.

WARNING
rious or fatal injuries may occur.
CAUTION
There is a risk of injury to the entire body, however there is no risk
of serious or fatal injuries.
NOTICE
Risk of damage to the machine. There is no risk of injury.

2 Safety regulations
These safety regulations correspond to the “Maintenance and special
work” section in the VDMA (German Engineering Federation) bro‐
chure “Safety manual for concrete delivery and placing machines”.
““Safety manual for concrete delivery and placing machines””.
The safety regulations in the Operating Instructions must also be fol‐

lowed for all maintenance and special work.
Special safety regulations may be necessary for some tasks.

These special safety regulations will only be found in the descrip‐
tion of the particular task.
We include here a listing of regulations and safety standards for

your information:
● DIN EN 12001:2012, Conveying, spraying and placing ma‐
chines for concrete and mortar
● DIN EN 60204-1:2014, Safety of machinery – electrical equip‐
ment on machines
● DIN EN ISO 12100:2011, Safety of machinery

Safety regulations
2.1 Basic principle

The safety regulations in the Operating Instructions for this machine
apply whenever the machine is operated.
2.1.1 Exclusion of liability
We state here expressly that Putzmeister accepts no liability for dam‐

age arising from incorrect or negligent operation, servicing or mainte‐
nance or as a result of use contrary to the designated use. This state‐
ment is particularly valid for modifications to, additions to and custom‐
isation of the machine that are liable to compromise safety. The facto‐
ry guarantee will no longer be valid in such cases.
2.2 Requirements for special work

As the operator, it is your responsibility to provide all the necessary
information to the personnel involved before special work or mainte‐
nance work is carried out. Someone should be nominated as the per‐
son responsible for this.
Carry out the maintenance and inspection operations and comply with
intervals specified in the Operating Instructions, including specifica‐
tions for the replacement of parts and equipment. These tasks may
only be carried out by qualified personnel.
Workshop equipment appropriate to the task in hand is absolutely

necessary for the execution of maintenance work.
If changes have been made to the machine, it must be checked by a

subject expert before recommissioning.
Secure a wide area around the maintenance area as far as is neces‐

sary.
A machine that has been completely shut down for maintenance and
repair work must be secured to prevent it being restarted inadvertent‐
ly:
● Lock the main control devices and remove the key.
● If a main switch is fitted, attach a warning plate to it.
Only carry out maintenance work if the machine is parked on level

and sufficiently supporting ground and is secured to prevent it rolling
away.

Safety regulations
Use specially designed or otherwise suitable climbing aids and work‐

ing platforms when carrying out assembly work above head height.
Never use machine parts as climbing aids. Keep all handgrips, steps,
railings, platforms and ladders free from dirt, snow and ice.
Carefully secure individual parts and large assemblies to lifting equip‐

ment when carrying out a replacement operation. Use only suitable
and technically perfect lifting equipment and suspension systems with
adequate lifting capacity. Never stand under suspended loads.
Attachment of loads and signalling to crane operators should only be

entrusted to experienced personnel. The signaller must be within vis‐
ual range of or in voice contact with the crane operator.
Observe national regulations when working with lifting equipment.
Work on chassis, braking and steering systems must only be carried

out by qualified personnel trained for such work.
Clean any traces of oil, fuel or preservatives from the machine, espe‐
cially connections and threaded unions, before carrying out mainte‐
nance or repair work. Do not use aggressive cleaning agents. Use
lint-free cleaning rags.
Bolted connections that you have loosened for carrying out mainte‐
nance and repair work must always be replaced or retightened in ac‐
cordance with manufacturer specifications.
Do not open gas-filled spring elements, as used on maintenance

flaps, for instance. The spring elements are filled with gas under high
pressure which can escape explosively if you attempt to open them.
Relieve the tension on systems under mechanical stress.
Be aware of hot functional fluids and surfaces (hydraulic fluid, hy‐

draulic fluid radiator, etc.).
Ensure that all functional fluids, consumables and replaced parts are
disposed of safely and with minimum environmental impact.
2.3 Welding
Only carry out welding, flame cutting and grinding operations on the
machine once this has been expressly approved by the manufacturer.
Only qualified personnel may carry out welding work in line with man‐
ufacturer specifications, especially on the placing boom, on the sup‐
ports, on load-bearing parts, on fuel and oil tanks or other compo‐
nents which are important for industrial safety. This work must be in‐

Safety regulations
spected by qualified welding personnel. The operator must document

the evidence of the formal qualifications of the welder and the quali‐
fied welding personnel.
Always attach the earth cable of the welding unit directly to the com‐
ponent which is being welded. The welding current must not flow
through hinges, cylinders, etc. Significant damage may be caused in
the event of a flash over.
Electronic components can be destroyed by stray voltage during arc

welding processes. For this reason:
● Disconnect the remote control cable from the control console.
● Disconnect all cables leading to the receiver of the radio remote
control system.
● Close connector sockets with caps.
● Disconnect the positive and negative leads from the battery.
Clean the machine and its surroundings of dust and flammable sub‐
stances and make sure that the premises are adequately ventilated
before carrying out welding, flamecutting and grinding operations,
otherwise there is a risk of explosion.
2.4 Working on the placing boom

Only carry out maintenance and repair work on the placing boom if
the placing boom is folded or properly supported, the engine is
switched off and the support legs are secured.
Support the placing boom arms before starting work on the valves,
cylinders or hydraulic lines on the boom.

Safety regulations
The delivery line was installed without tension with the placing boom
in the driving position and can only be replaced without difficulty in
this condition. Stresses may be generated on folding if the delivery
line is replaced when the placing boom is unfolded.
Do not remove the entire delivery line but rather replace the delivery
line boom arm by boom arm, for example. Otherwise, the pivot points
of the new delivery line will have to be redetermined using special
equipment.
2.5 Safetyrelevant components

Work on safety-relevant components requires particular specialist
knowledge.
The following activities in particular must only be carried out by quali‐

fied personnel that have been authorised by the manufacturer:
● Repairing, replacing or adjusting safety-relevant components and
adjustable devices (pressure limiting valves, potentiometers, fluid
flow limiters, hydraulic cylinders, sensors, etc.)
● Removing lead seals
Modifications to the machine data (in particular, increasing pressures,

modifying speeds, etc.) are not permitted.
2.6 Software
If a machine is equipped with software, the software may only be
used as is provided for in the manufacturer’s Operating Instructions.
Only persons authorised by the manufacturer may intervene in the

machine's software. This also applies to updates.
Unauthorised interventions in the machine's software may lead to se‐

vere damage and accidents.
2.7 Protective and safety equipment

Any safety equipment removed for maintenance purposes must be
refitted and checked immediately upon completion of this work.
All equipment required for safety and accident prevention (warning

signs and information plates, grilles, guards, etc.) must be in place.
Such equipment must not be removed, modified or damaged.

Safety regulations
Keep all warning signs and information plates on the machine com‐
plete and in a perfectly legible condition.
It is your responsibility as operator to ensure that any warning signs

and information plates that have been damaged or rendered illegible
are replaced without delay.
2.8 Electrical power
2.8.1 General
Work on electrical systems or operating equipment must only be car‐

ried out by qualified personnel. For further information on machines
that are operated using the site power supply, see also the (Power at
the construction site P. 2 — 8) section.
Machine components which are to undergo maintenance work must

be deenergised. Ensure that disconnected machine components can‐
not be restarted. First of all, you must check that deenergised parts
are indeed deenergised, then earth and shortcircuit them and isolate
adjacent live parts.
Disconnect the negative lead from the battery before starting any
work on the electrical system of machines with an internal combustion
engine. When reconnecting, connect the positive terminal first, and
then the negative terminal.
Before starting work on highvoltage assemblies and after cutting the

power supply, you must connect the supply cable to earth and short‐
circuit the components, particularly the capacitors, with a rodtype
earth electrode.

Safety regulations
If work is to be carried out on live parts, the presence of a second

person is required who can switch off the power supply to the ma‐
chine in the event of an emergency. Secure the working area with a
red-and-white safety chain and a warning plate. Use insulated tools
only.
2.8.2 Electrical components
Control cabinet, motor and control elements are protected as stand‐

ard in accordance with degree of protection IP 54.
IP 54 means:
● Complete protection against contact with live components or inter‐
nal moving parts. Protection against damaging dust deposits.
● Water spraying on the equipment from random directions must not
have a damaging effect.
Use only original fuses with the specified voltage rating. Bridging or
the use of fuses with too high a rating can irreparably damage the
electrical system. You must switch off the machine immediately if a
fault occurs in the power supply.
2.8.3 Power at the construction site
The power on the construction site must be supplied from a special

feed point (construction site power distribution point). Machines with
an electric motor must not be connected to the mains power supply.
Only trained and qualified personnel are permitted to work on electri‐

cal systems with an operating voltage of more than 25 volts alternat‐
ing voltage or 60 volts direct current. Only such qualified personnel
may install, connect, disconnect and open electrical control cabinets.
An electric shock (possibly with fatal consequences) may be the re‐

sult of touching machines with electric motors or contact with other
electrical cables if the electrical connection has not been made prop‐
erly or the supply cable is damaged.
2.9 Hydraulic systems
2.9.1 General
Work on hydraulic systems must only be carried out by qualified per‐

sonnel.

Safety regulations
Always wear your personal protective equipment when carrying out

work on the hydraulic system. Escaping fluid is toxic and can pene‐
trate the skin.
Injection through the skin is a major medical emergency. In the event

of injuries caused by pressurised fluid, inform the company medical
officer and call a medical specialist immediately. This also applies for
injuries which may seem only slight. Hydraulic fluid which has pene‐
trated underneath the skin must be removed immediately. Otherwise,
there is a risk of death due to impaired blood circulation and infec‐
tions.
Before starting repair work, depressurise the system sections and

pressure lines (hydraulic system, pneumatic system, delivery line)
that are going to be opened in accordance with the assembly descrip‐
tions.
Never work on systems that are still under pressure. Switch the hy‐
draulic pump drive and the engine off. Otherwise there is a risk of in‐
jury caused by functional fluids escaping under pressure. If there is a
hydraulic accumulator, open the accumulator dump valve to prevent
any machine movements caused by residual pressure. Modifications
to the hydraulic accumulator are prohibited.
Be aware that enclosed hydraulic fluid can remain pressurised for a

certain length of time. Do not open any hydraulic systems if they are
under load from an external force (particularly from a raised placing
boom).
Lay and install hydraulic lines in accordance with the current rules of
engineering. Connections must be fitted at the appropriate points. Fit‐
tings and the length and quality of the hoses must comply with re‐
quirements.

Safety regulations
The hydraulic system must be properly vented after all maintenance

work. Otherwise there is a risk of injury caused by swinging and tele‐
scopic support legs extending rapidly, the placing boom lowering, etc.
Open vent valves very carefully until hydraulic fluid starts to escape.
You should on no account open vent valves further than necessary or
go so far as to remove them.
Damaged hydraulic lines must be replaced rather than repaired. You

must replace damaged or saturated hydraulic hoses immediately. Hy‐
draulic fluid spray escaping under pressure can cause injuries and
fires.
2.9.2 Replacing hydraulic hoses
During retesting, hydraulic hoses must be checked by a subject ex‐

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

The place of work in normal operation is with the remote control. For
this reason, it is not possible to specify a particular place of work for
the machine operator. Take the values for the sound pressure level
and sound power level from the machine Operating Instructions.
Wear suitable personal protective equipment in the vicinity of the ma‐

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

their personal hearing protectors. You are responsible for ensuring
that your personnel comply with this regulation.
All soundproofing equipment must be fitted and in perfect condition.

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

Vehicle exhaust gases contain constituents that can be deadly or car‐
cinogenic. Operate internal combustion engines and fuel-operated
heating systems only in adequately ventilated premises. Before start‐
2 — 10 Service Instructions 214490294_2021-12-20_en

Safety regulations
ing up the engine in enclosed spaces, make sure that there is ade‐
quate ventilation and direct the exhaust gases away from the place of
work.
Wear personal protective clothing and equipment for all work in which
exhaust gases or particles of building material can enter the body
through the respiratory passages. Comply with the information issued
by the manufacturer of the building material.
2.12 Functional fluids

When handling oils, greases and other functional fluids, observe the
safety regulations applicable to the product concerned (see the safety
data sheet).
Oils, fuel and other functional fluids may be hazardous to health upon
contact with the skin, etc. You must therefore always wear personal
protective clothing and equipment when you are handling toxic, caus‐
tic or other functional fluids that are hazardous to health and always
take note of the manufacturer’s information.
Take care when handling toxic and caustic functional fluids (brake flu‐
id, battery acid, water glass, concrete set accelerating admixtures, ce‐
ment, etc.). Building materials containing cement have a highly alka‐
line effect when they react with water (and also with perspiration). Ad‐
mixtures are toxic and caustic.
Cleaning agents, concrete release agents, preserving agents etc. pro‐

pelled by compressed air can cause very serious damage to the res‐
piratory tract if a respiratory protection mask is not worn. Spray mist
enters the lungs very easily.
Frequent injuries are eye injuries caused by concrete spatter, water

glass or other chemical substances.
214490294_2021-12-20_en Service Instructions 2 — 11

Safety regulations
Take care when handling hot functional fluids and consumables (risk
of burning or scalding).
Have used operating equipment and functional fluids such as filters,

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

To dispose of the machine, you must proceed in accordance with all
points in the disposal regulations which apply in your country.
During the disposal operation, you must observe the following in par‐
ticular:
● Remove the functional fluids, particularly hydraulic fluids, engine
oils, fuel, brake fluid, concrete admixtures, any environmentally
hazardous functional fluids or functional fluids which are hazard‐
ous in any other way, and dispose of these correctly.
● Remove the operating equipment, particularly the hydraulic fluid
reservoir, hydraulic cylinder, hydraulic fluid radiator, hydraulic lines
and hoses and other components which may contain residual func‐
tional fluids, and dispose of these correctly.
● Remove the steel structure and dispose of it correctly, e.g. by recy‐
cling.
● Dispose of the truck or the drive unit correctly.

3 Special operating modes
WARNING
Risk of death during special operation
1. Only ever use special operating modes if you have received
training on these by the manufacturer of the machine.
2. Only ever use special operating modes if you are authorised to
do so by the operating company of the machine.
The machine's special operating modes are described in this chapter.

Special operating modes are, in particular:
● Operation in situations with increased risk.
● Operation with limited functionality.

Special operating modes
3.1 Recovery with onboard equipment

You must stop the site use if the on-board electronics fail.
The delivery system may become damaged if concrete sets in it. You
can recover the machine without support from the on-board electron‐
ics.
WARNING
Risk of death during special operation
1. Only ever use special operating modes if you have received
training on these by the manufacturer of the machine.
2. Only ever use special operating modes if you are authorised to
do so by the operating company of the machine.
Recovery of the machine is a special operating mode. This method

is not suitable for continuing site use. You will need assistance
from at least one other person to be able to recover the machine.
3.1.1 Preparing for recovery
The machine's EMERGENCY STOP buttons do not work while the

machine is being recovered.
1. Cover all EMERGENCY STOP BUTTONS on the machine while it is
being recovered.
The agitator safety cutout is inactive while recovering the machine.

2. When recovering the machine, call in auxiliary personnel to cor‐
don off and monitor the entire working area and danger zone.

3.1.2 Setting up the pump control system
The pump control system is located behind the control cabinet.
Item Designation
1 Hydraulics control block of the core pump
Figure 1: Hydraulics control block of the core pump
Item Designation
1 Switch over the transfer tube
2 Fill the accumulator
3 Move the delivery pistons
4 “Adjust output” handwheel

3.1.3 Emergency operation of the core pump
You can operate the core pump and water pump manually if the on-
board electronics fail.
WARNING
Risk of death due to moving components
During emergency operation, moving components may present a
danger to personnel.
1. Ensure that nobody is in the danger zone before emergency op‐
eration.
2. Announce the emergency operation of moving components in a
clear and timely manner.
3. If in doubt, instruct auxiliary personnel to monitor the danger
zone.
Prerequisites:
✓ You have prepared for recovery.
(Preparing for recovery P. 3 — 3)
1. Make sure that the grille is closed.
The following steps are absolutely necessary for the core pump to
function.
2. Remove the casing in front of the pump control system.
If the electronics fail, you need to manually adjust the output with a
handwheel on the control block in order for the delivery pistons to
move.
3. Turn the handwheel anticlockwise.
⇒ The output increases.
4. Extend the retracted delivery piston.
You can fill the accumulator while the delivery pistons are moving.
5. Fill the accumulator.

The accumulator is emptied as soon as you let go of the valve.
6. Check the pressure gauge to see if the pressure required for

switching over the transfer tube is reached.
⇒ The indicator has reached the marking for the switchover
pressure.
7. Switch over the transfer tube.
8. Repeat the procedure.

9. Turn the “Adjust output” handwheel clockwise.
⇒ You have reduced the output to zero.
10. Fit the casing in front of the pump control system again following
emergency operation.

4 Maintenance
Carry out all specified checks, inspections and maintenance work
conscientiously. Otherwise we will refuse any liability or warranty
claim. Contact the Putzmeister After Sales department if you have
any questions.

Maintenance
4.1 Maintenance intervals

The following table shows the intervals of the individual repair actions.
The associated instructions can be found further on in this chapter.
NOTICE
Damage caused by inadequate maintenance
1. Have the first After Sales service after 100 operating hours car‐
ried out by a Putzmeister After Sales service engineer. The ma‐
chine operator responsible for the machine should be present
during this service.
2. If several intervals are listed for maintenance work, apply the in‐
terval that occurs more frequently when using your machine.
Hours (h) = operating hours of the assembly
Assembly Action Interval

daily 500 h annually other
rs
General Visual inspection of electrical ca‐ ✓
bling
Visual inspection and function ✓
check of all safety equipment
Check the bolted connections ✓
against the tightening torque ta‐
ble
Hydraulics Check hydraulic fluid level ✓
Visual check of the lines (dam‐ ✓
age/leaks)
Check the hydraulic cylinder for monthly
leak tightness (visual inspection)
Clean the hydraulic fluid radiator ✓
Replace the hydraulic fluid (fol‐ ✓ ✓
lowing fluid analysis)

Maintenance
Assembly Action Interval

daily 500 h annually other
rs
Replace hydraulic hoses 6 years (in‐
cluding a stor‐
age period of 2
years)
Hydraulic fluid Check the contamination indica‐ ✓
filter tor
Replacing the pressure filter ✓ as required
Mixer shaft Check concentricity ✓
drive
Transfer tube Check wear ✓
Check and adjust the seal gap ✓
Check the tightening torque of ✓
the bolts
Lubrication (Lubricating
the transfer
tube
P. 4 — 36)
Delivery line Safety lock of the couplings ✓
Check the wall thickness 50 hrs
Delivery piston Check the bolted connections 250 hrs
and retaining rings
Check wear weekly
Components Check wear 50 hrs
that come into
contact with
concrete
Vibrator Check the bolted connections weekly
Centralised lu‐ Check the grease fill level ✓
brication sys‐
tem
Drive motor In accordance with the motor manufacturer’s maintenance information

Maintenance
4.2 Residual risks during maintenance, inspection and

repair work
WARNING
Risk of injury
1. Wear your personal protective equipment when performing
maintenance, inspection and repair work.
2. Always wear a safety helmet and safety footwear.
3. Wear your protective goggles when handling compressed air,
corrosive liquids and gases and paints.
4. Read the “Safety regulations” chapter for more information on
personal protective equipment.
4.2.1 Personal protective equipment
See the Safety regulations chapter of the Operating Instructions for

personal protective equipment requirements.
4.2.2 Personnel requirements
Maintenance, inspection and repair work must only be carried out by

qualified personnel. “Qualified personnel” means those who have
completed specialist training for carrying out such work. This training
qualifies them to carry out the activity concerned.
4.2.3 Auxiliary devices
Workshop equipment suitable for the work is absolutely necessary for

carrying out maintenance, inspection and repair work.
If you do not have access to qualified personnel, suitable workshop

equipment, etc., you should commission the manufacturer's After
Sales Department to assist with maintenance of your machine or
component.

Maintenance
4.2.4 Residual risks
During maintenance, inspection and repair work, there are particular

risks of an accident, because, for certain activities, protective devices
must be removed, for example. There follows a list of residual risks in
particular, which may be present during maintenance, inspection and
repair work.
WARNING
Risk of injury
During work which cannot be carried out at ground level, there is a
risk that you may fall from a large height.
1. Use suitable platforms or work stands.
2. Ensure that you are secure by using safety harnesses, railings
or walkway barriers.
3. Never use machine parts as climbing aids.
4. Keep all handgrips, steps, railings, platforms, work platforms
and ladders free from dirt, snow and ice.
5. Observe the relevant national regulations.
WARNING

Maintenance
WARNING
Risk of injury from the machine starting unexpectedly
1. Put the machine out of service before starting maintenance, in‐

spection and repair work.
2. Secure the machine against unexpected start up (for example,
pull out the ignition key and lock it away, or attach a warning
plate).
3. Call a second person to help you if necessary.
WARNING
Risk of injury
Damage to pipes and threaded unions may lead to high pressure in‐
jection of pressurized hydraulic fluid and to injury as a result of be‐
ing struck by detached hydraulic hoses.
1. Regularly inspect all lines and threaded unions for leaks and
external damage before all pumping operations.
2. Inspect the threaded unions and hoses after each replacement.
4. Secure the hydraulic hoses tightly in place when loosening the
threaded unions.
WARNING
Risk of injury from compressed air
1. Put the machine out of service before starting maintenance, in‐
spection and repair work.
2. Depressurize the machine compressed air system.
WARNING
Risk of injury
▶ Firmly hold the cover of the stowage compartment so that it is
secure while opening the stowage compartment.

Maintenance
CAUTION
Risk of injury from hot surfaces and functional fluids in the machine
Risk of burning to various parts of the body from hot surfaces in the
machine's motor area.
1. Do not carry out any service work until the motor, surfaces and
functional fluids have cooled down.
4.3 Specifications for bolted connections

The following specifications apply if there are no other specifications
in the relevant chapters of the Operating Instructions or in spare parts
sheets.
Tightening tool:
● Manual torque wrench
in accordance withDIN EN ISO 6789
● Preferably version with display
● Suitable for specified torque
Condition of the connecting elements:

● Free from corrosion
● Free from contamination
● Free from lubricants
● Bearing surfaces parallel to bolt head, nut, washer, etc.
● Primer and paint correspond to the delivery condition
4.4 General tightening torques

Tightening torques depend on the following values:
● bolt grade
● thread friction
● bolt head bearing area
The values given in the following tables are for guidance. These val‐
ues should only be used if no other values are specified in the rele‐
vant chapters of the Operating Instructions or in spare parts sheets.

Maintenance
Always replace bolts with bolts of the same size and grade.
Replace bolts with adhesive in the locking threads and selflocking

nuts after disassembly.
4.4.1 Set screws and nuts
▶ The maximum tightening torques for set screws and nuts can be
found in the spare parts list.
4.4.2 Fitting threaded unions
Threaded unions
RAD Model MA[Nm]
6 L 20
8 L 40
10 L 45
12 L 55
S 80
15 L 70
16 S 130
18 L 120
20 S 250
25 S 400
30 S 500
38 S 800
RAD = pipe external diameter
MA = tightening torque

Maintenance
Figure 2: Tightening the flared screwed joints
1. Using a spanner, tighten the union nut without excessive force.

For flanged screw joints and profiled ring joints:
2. Use another spanner to hold the threaded connection in place
while doing so.
4.4.3 Reassembly of WALFORMplus threaded unions
This section describes what must be borne in mind during reassembly

of WALFORMplus threaded unions.

Maintenance
4.4.3.1 Tightening torques
1 2
4 3
Figure 3: WALFORMplus threaded union setup
Item Designation
1 Threaded connection
2 Union nut
3 Pipe
4 Seal
The tightening torques are guide values, and only apply to opti‐
mum conditions. The torques may deviate substantially because of
tolerance influences, pipes fitted under tension and incorrect lubri‐
cation.
WALFORMplus threaded union tightening torques

RAD Model MA[Nm]
6 L 30
8 L 35
10 L 40
12 L 55
15 L 80

Maintenance

RAD Model MA[Nm]
18 L 110
22 L 140
28 L 210
35 L 300
42 L 400

RAD Model MA[Nm]
6 S 35
8 S 40
10 S 55
12 S 70
16 S 110
20 S 150
25 S 210
30 S 280
38 S 410
4.4.3.2 Fitting WALFORMplus threaded unions
For the reassembly of the WALFORMplus threaded union, proceed

as follows:
1. Check the thread for cleanliness and damage.
2. Clean the thread.

Maintenance
▶ Replace the parts that have a damaged thread.

3. Each time you undo a connection, check the seal for damage,
▶ and replace it if necessary.
4. For threaded unions made of rustproof steel, grease the thread
and the reshaped area of the pipes with an adequate amount of
EATONABF grease.
5. Pull the gasket onto the reshaped pipe as far as the stop.
Retighten the union nut using the appropriate torque shown in the
table above.
6. Tighten the union nut using a spanner, while at the same time
holding the threaded connection with a spanner/wrench.
4.5 Functional fluids

This section lists all the functional fluids used in your machine.
NOTICE
Machine damage caused by lubricants with dangerous additives
▶ Never use hydraulic fluids or lubricants with additives such as
molybdenum.
4.5.1 Hydraulic fluids
See alsohttps://www.putzmeister.com/documents/58405/5728115/
CT_4748-2_DE_Hydraulikfluide.pdf
The hydraulic system is filled with one of the following hydraulic fluids:
● Mineral hydraulic fluid (HLP)
● Synthetic ester-based biodegradable hydraulic fluid (HEES)
● Non-readily flammable hydraulic fluid (HFC)
See the machine card to find out what the initial filling was in your
machine.

Maintenance
Use only Putzmeister hydraulic fluid, material no. 239879002, if your

machine was filled with fire-resistant hydraulic fluid ex works (HFC as
specified in the 7th Luxembourg Report).
Use only Putzmeister hydraulic fluid, material no. 484527, if your ma‐
chine was filled with synthetic ester ex works.
We have listed all suitable hydraulic fluids in the table below. Putz‐
meister accepts no liability for the quality of the hydraulic fluids listed
or for changes in quality made by the manufacturers without changing
the grade designation.
Mineral oil Synthetic ester Aqueous solution

HLP HEES 46 HFC 46
Classification DIN 51502:1990 DIN 51502:1990 DIN 51502:1990
DIN ISO 6743-99:2012 DIN ISO 6743-99:2012 DIN ISO 6743-99:2012
Requirement DIN 51524-2:2017 VDMA 24568 VDMA 24317/VDMA
DIN EN ISO 24320
6743-4:2015 4746/10/91
VDMA 24318
Viscosities and particu‐ DIN ISO 3448:2010 DIN ISO 3448:2010 DIN ISO 3448:2010
lar properties 32 mm2/s ISO VG 46 mm2/s ISO VG 46 mm2/s ISO VG
● Use at -15 °C to +80 ● Use at -10 °C to ● Use at -20 °C to +60
°C +80 °C °C
46 mm2/s ISO VG ● Rapidly biodegrada‐ ● Non-readily flamma‐

ble ble
● Use at -10 °C to +90
°C
68 mm2/s ISO VG
● Use at 0 °C to
+95 °C

Maintenance
Mineral oil Synthetic ester Aqueous solution

HLP HEES 46 HFC 46
Initial filling HLP 32 ● Material number: ● Material number:
484527 239879.002
● Material number:
490984 ● Manufacturer: BE‐ ● Manufacturer:
CHEM HYDRO‐ FUCHS HYDRO‐
HLP 46 STAR HEES 46 EEL THERM 46 M
000171.007
HLP 68
279845.009
Changeover guidelines - VDMA 24569 -
4.5.1.1 Level of contaminant
The level of contaminant 19/16/12 is required for the hydraulic system

according to ISO 4406:2017.
4.5.1.2 Hydraulic fluid reservoir capacity
Capacity at the “min” marking 33 litres

Capacity at the “max” marking 46 litres
Table 1: Hydraulic fluid reservoir capacity
Conditions for the hydraulic fluid level inspection:

● The machine is horizontal
● The hydraulic fluid is at ambient temperature

Maintenance
4.5.1.3 Notes on mixing hydraulic fluids
NOTICE
Machine damage from incorrect hydraulic fluid mixtures
▶ Do not mix hydraulic fluids of different types ‐ in particular, do
not mix biologically degradable hydraulic fluids with mineral hy‐
draulic fluids.
When hydraulic fluids of different viscosity grades are mixed, the new
viscosity is determined by the mixing ratio. Mixing hydraulic fluids
from different manufacturers may lead to a loss of quality. Always
consult the manufacturer before mixing fluids.
HEES synthetic esters and HFC aqueous solutions from different

manufacturers must not be mixed together without prior approval from
the manufacturers concerned.
Putzmeister accepts no liability for damages caused by mixing hy‐

draulic fluids from different manufacturers.
4.5.1.4 Notes on fluid changes
Take note of VDMA (German Engineering Federation) changeover

guidelines and manufacturer instructions when carrying out a fluid
change. Please contact the manufacturers concerned if you have any
queries regarding the suitability and miscibility of hydraulic fluids.
You must first consult Putzmeister Department APS if you wish to use
hydraulic fluids with viscosity grades other than VG 46 (e.g. at higher
ambient temperatures).
The proportion of residual fluid must not be greater than 2% after a

fluid change from HLP to HEES.
● A so-called flushing cycle must be carried out using the full quanti‐
ty of the new hydraulic fluid.
● For reasons of seal compatibility, a fluid change must be carried
out no later than 6 months after the machine is started up.
● The new liquid may dissolve existing deposits.
All filters must be replaced after 50 operating hours.

Maintenance
When the hydraulic fluid is changed, approx. 10 - 15% of the old

hydraulic fluid remains in the system (in cylinders, pumps, lines,
etc.).
4.5.2 Lubricant analysis
If a hydraulic fluid used impairs your machine, we can carry out a lu‐
bricant analysis for you. Contact the Putzmeister After Sales depart‐
ment and ask for our analysis set. We will carry out a lubricant analy‐
sis to determine the cause.
4.5.3 Storage of lubricants
NOTICE
Environmental pollution
Lubricants and functional fluids are damaging to the environment.
1. Carefully collect all functional fluids and operating equipment
(e.g. used oil, including biologically degradable oil), filters and
auxiliary materials.
2. Dispose of these materials separately from other waste.
3. Keep the different categories of used oil separate in order to
keep disposal costs as low as possible.
4. Comply with the relevant national and regional regulations.
5. Only work with waste disposal companies who are approved by
the responsible authorities.
Do not store oils and greases in the open air. Weather variations may
cause water to be absorbed through the bung hole.
Only ever store the barrels lying on their side and supported on tim‐
ber blocks, with the bung hole facing upwards.
4.5.4 Lubricant recommendation
We have listed all suitable lubricants in the tables below. Putzmeister

accepts no liability for the quality of the lubricants listed or for
changes in quality made by the lubricant manufacturers without
changing the grade designation.

Maintenance
Gearboxes and drive motors are filled by the respective manufac‐

turer. Maintenance only in accordance with the relevant manufac‐
turer’s specifications.
4.5.4.1 Transmission fluid
Rotor gearbox Boom slewing Mixer drum gearbox Transfer gear‐

gear transmission box
Requirements DIN 51517-3:2018 DIN 51517-3:2018 DIN 51517-3:2018 see spare parts
standard sheet
Characteristics synthetic mineral mineral
Viscosity grade, CLP 220 CLP 220 CLP 220
NLGI Class
Material no. 295246.006 000101.006 000101.006
4.5.4.2 Greases
Greasing (manual) Centralised lubrication system

Marked in accordance withDIN K2K30 K1K30
51502:1990
Requirements standard DIN 51825:2004 DIN 51825:2004
Characteristics mineral, lithium soap
Viscosity grade NLGI Class 2 NLGI Class 1
NLGI Class DIN 51818:1981 DIN 51818:1981
Material no. 360000.009 360001.008
We recommend the following grease, rather than those specified in

the lubricant table, should you wish to fill the centralised lubrication
system with a low temperature grease in extremely cold condi‐
tions:
Marking in accordance with DIN 51502:1990: K E 2G-60, NLGI

Class 2

Maintenance
4.6 Maintenance work
4.6.1 Carrying out visual checks
The following visual checks must be carried out before any mainte‐
nance work. The control deadlines can be found in the overview at
the start of this chapter.
WARNING
Risk of injury from a fire and risk of explosion posed by damaged
electrical lines
Risk of injury from fire and risk of explosion posed by flash overs
from damaged electrical lines, particularly in the case of high levels
of humidity in the air or surroundings. If using in an explosive at‐
mosphere, there is a risk of explosion and fire caused by sparking.
▶ Inspect all electrical lines particularly carefully and closely.
There are specific risks of accidents associated with maintenance,

inspection and repair work. For this reason, read the chapter
“Safety regulations” and the description of the residual risks in
“Maintenance, inspection and repair work” at the start of this chap‐
ter.
See also the following sections:

● (Replacing the pressure filter P. 4 — 30)
● (Maintaining the hydraulic lines P. 4 — 25)
The following special tools are required:

● No special tools are necessary.
4.6.1.1 General
The following general visual inspections should be carried out before

any maintenance work or use.
1. Check the fill levels of the functional fluids.

2. Check that all safety equipment is available and in a fully func‐
tioning condition.

Maintenance
4.6.1.2 Electrical system
1. Check that all electrical connections are secure and free from
corrosion.
2. Check that the electrical cables have no breaks.
3. Check the insulation on the electrical cables.
The electrical system is damaged

▶ Have the damage rectified by a qualified electrician immedi‐
ately.
4.6.1.3 Hydraulics
Timely detection and rectification of damage to the hydraulic sys‐

tem can prevent lengthy downtimes and high repair costs.
1. Check that the display on the vacuum meter of the vacuum filter
is still in the green range.
The displays are in the red area?

▶ Replace the vacuum filters. (Replacing the hydraulic fluid filter
P. 4 — 29)
2. Check the contamination indicator of the pressure filter. (Replac‐

ing the pressure filter P. 4 — 30)
3. Check the hydraulic fluid radiator for contamination and deposits.
4. Check all hydraulic hose lines for leaks. (Checking hydraulic hose
lines for leaks P. 4 — 26)
5. Check all hydraulic unions for tightness and leaks. (Checking the
threaded unions P. 4 — 28)
4.6.2 Hydraulic system
4.6.2.1 Replacing the hydraulic fluid
The following maintenance work information describes how to carry

out a full fluid change on the hydraulic system. The fluid change inter‐
vals can be found in the overview at the start of this chapter.

Maintenance

ter.

● (Replacing the hydraulic fluid filter P. 4 — 29)
Fluid analysis
▶ Carry out a fluid analysis. (Lubricant analysis P. 4 — 17)
Result Corrective measure

Green check mark None
Yellow question mark Query the recommended measure
with the Putzmeister After Sales de‐
partment.
Red exclamation mark Have the hydraulic fluid completely
changed by the Putzmeister Service
department.
Changing the hydraulic fluid in the hydraulic fluid reservoir
NOTICE
Machine damage
The hydraulic fluid change described does not replace the complete
hydraulic fluid change by the Putzmeister Service department.
▶ We recommend having the hydraulic fluid completely changed
by the Putzmeister Service department.

Maintenance
NOTICE
Damage to the machine due to hydraulic systems that are not
clean.
Particles of dirt may cause valves to be scored, pumps to seize and
throttle and control bores to become blocked.
1. Prevent dirt and other impurities from entering the hydraulic
system.
2. Allow the hydraulic fluid drums to stand for a prolonged period
before removing the fluid.
3. Clean bungs and filler lids as well as the area around them be‐
fore opening.
4. Where possible, fill the hydraulic system using a charging set.
NOTICE
Prerequisites:
✓ You have carried out a lubricant analysis.
✓ The Putzmeister Service department has confirmed that changing
the hydraulic fluid in the hydraulic fluid reservoir will be sufficient
for the measured degree of contamination.
✓ The hydraulic fluid barrels have stood still for some time before the
hydraulic fluid is removed from them.
✓ You did not roll the hydraulic fluid barrels to the tapping point.

Maintenance
Draining the hydraulic fluid
1. Switch off the engine.

2. Press the EMERGENCY STOP BUTTON.
3. Dump the accumulator pressure completely.
4. Check the pressure gauge to ensure that the hydraulic fluid pres‐
sure in the plant has been completely dumped.
5. Remove the KEY from any KEYSWITCHES that are present.
6. Cordon off the working area.
7. Disconnect the power supply.
8. Place warning notices on blocked control and setting devices.
9. Clean bungs and filler lids as well as the area around them before
opening.
10. Prevent dirt and other impurities from entering the hydraulic sys‐
tem.
⇒ You have prepared for changing the hydraulic fluid.
11. Open the drain cock on the bottom of the hydraulic fluid reservoir.
Figure 4: Draining the hydraulic fluid
12. Drain off the hydraulic fluid.

If there is a cleaning port on the side of the hydraulic fluid reser‐
voir:
13. Open the wash-out port.
14. Wipe out all the openings with a lint-free cloth. When doing so,
reach as far as possible inside the tank.
15. Close the drain cock on the bottom of the hydraulic fluid reservoir.

Maintenance
Filling the hydraulic fluid reservoir
Figure 5: Filling the hydraulic fluid reservoir
1. Use only the hydraulic fluids specified in the lubricant recommen‐

dation.
3. Fill the hydraulic fluid reservoir with new hydraulic fluid via the
screen in the filler pipe up to the “Maximum” marking.
4. Remove contaminant deposits from the hydraulic fluid radiator.
5. Check all threaded unions on the hydraulic fluid reservoir and re-
tighten them if necessary.
➙ You have changed the hydraulic fluid in the hydraulic fluid reser‐
voir.
Restoring the operating state
1. Place the KEY into any KEYSWITCHES that are present.

2. Connect the power supply.
3. Remove the information plates you have fitted for the mainte‐
nance work.
You can enable the working area.
4.6.2.2 Carrying out function checks
The following maintenance work information describes checking of

machine functions. The inspections are carried out with the machine
running.

Maintenance

ter.

● No further repair work is necessary.
● Pressure gauge
● Connections for the measuring points specified in the hydraulic cir‐
cuit diagram.
Work on the hydraulic system must only be carried out by qualified

personnel authorized by Putzmeister. Notify the Putzmeister After
Sales department or the dealer or agency that you work with im‐
mediately if you find anything wrong.
1. Measure the pump pressures on the centralized gauge ports.

2. Compare the pressures of the pumps to the values entered in the
measurement record.
3. Check to ensure that the accumulator is working correctly. (In‐
specting the accumulator P. 4 — 33)
4.6.2.3 Maintaining the hydraulic lines
The maintenance intervals can be found in the overview at the start of

this chapter.

Maintenance
NOTICE

ter.

MA The following tightening torques are required:

● The tightening torques can be found in the corresponding spare
parts list.
Checking hydraulic hose lines for leaks
1. Check all hydraulic hose lines (including the fittings) while the
machine is running.
2. Replace the hydraulic hose lines immediately if the smallest of
damage or even signs of impending damage appear.

Maintenance
Figure 6: Checking hydraulic hose lines
Dark and moist patches on the fitting are external signs of incipient
damage.
3. Check the hydraulic hose lines for kinks, cracks or porous surfa‐
ces.
4. Ensure that the hydraulic hose lines are properly routed.
Replacing hydraulic hose lines
WARNING
Risk of injury
Mechanically pre-stressed hydraulic hose lines can become detach‐
ed and cause injury due to impact.
▶ Exercise the necessary caution.
When replacing hydraulic hose lines, proceed as follows:

1. Shut the machine down and secure it against unauthorized start‐
ing up.
2. Completely dump any (residual) pressure that may remain in the
hydraulic system.
3. Take care when undoing the joints.
4. Seal the connection points immediately using a plug if you have
removed the old hydraulic hose lines.
5. Ensure that there is no dirt ingress into the hydraulic circuit and
that the hydraulic circuit does not run dry.

Maintenance
Hydraulic hose lines should not be more than six years old, includ‐
ing a storage time of two years. Please note the date of manufac‐
ture on the hydraulic hose lines.
The following factors in particular accelerate wear on hydraulic

hose lines:
● Strong sunlight
● Heat
● Chemical effects
6. Keep the hydraulic hose lines clean.

7. Fit the hydraulic hose lines so that they are free from kinks and
abrasion.
8. Vent the hydraulic system.
9. After fitting new hydraulic hose lines, perform a test run and
check all hydraulic hose lines again.
Checking the threaded unions
Figure 7: Tightening the flared screwed joints
1. Check whether the threaded unions are leak-tight.

2. Only tighten the flared screwed joints with the permitted tighten‐
ing torque.
3. Tighten the threaded unions until there is a clearly noticeable
power increase.
4. If the threaded unions leak again, replace them.
5. For tightening torques, see the “Threaded unions” table at the
start of this chapter.

Maintenance
4.6.2.4 Replacing the hydraulic fluid filter
This chapter describes how to replace the following filters:

● Pressure filter
NOTICE
Material damage
Commercially available filter elements do not meet Putzmeister's re‐
quirements.
Cleaned filter elements have a lower flow rate than new filter ele‐
ments.
1. Only use original Putzmeister filter elements.
2. Always replace filter elements rather than cleaning them.
NOTICE

ter.


Maintenance

Prerequisites:
✓ The hydraulic fluid barrels have stood still for some time before the
hydraulic fluid is removed from them.
✓ You did not roll the hydraulic fluid barrels to the tapping point.
Preparing the replacement of the hydraulic fluid filters
1. Switch off the hydraulic pumps.

4. Check the pressure gauge to ensure that the hydraulic fluid pres‐
sure in the plant has been completely dumped.
5. Switch off the remote control.
6. Secure the machine to prevent unauthorised start-up.
7. Remove the key from any keyswitches that are present.
8. Disconnect the power supply.
9. Cordon off the working area.
10. Place warning notices on the blocked control and setting devices.
11. Clean bungs and filler lids as well as the area around them.
12. Prevent dirt and other impurities from entering the hydraulic sys‐
tem.
Replacing the pressure filter
Prerequisites:
✓ You have prepared for replacing the filter.
(Preparing the replacement of the hydraulic fluid filters P. 4 — 30)
Do not leave the hydraulic fluid reservoir lid open for longer than
necessary.

Maintenance
Figure 8: Setup of the pressure filter
Item Designation
1 Filter element
2 Filter housing
1. Unscrew the filter housing.

2. Remove the filter element.
3. Thoroughly clean the filter housing with a clean cloth.
4. Inspect all O-rings and other gaskets in the filter sets, and replace
them if damaged.
5. Install a new filter element.
6. Screw the filter housing back on .
7. Connect the power supply.
➙ You have replaced the pressure filter.

Maintenance
4.6.3 Core pump
4.6.3.1 Checking the concentricity of the mixer shaft

ter.

● Dial gauge with stand
The mixer shaft will damage the hopper if it does not run concentrical‐
ly. The deviation in concentricity on the mixer shaft is transferred to
the agitator drive. It is possible to measure the movements of the agi‐
tator drive.
Item Designation
1 Distance between dial gauge and hopper wall:
250 mm
2 Agitator drive
1. Fasten the dial gauge stand to a reference surface that is not on

the hopper or agitator drive.
2. Place the dial gauge on the agitator drive housing.

Maintenance
The agitator drive housing does not turn with the mixer shaft.
3. Switch the machine on.

5. Using the dial gauge, measure how far the agitator drive moves.
⇒ The deviation in concentricity is no more than ±1 mm.
6. Repeat the process in at least eight more positions around the
agitator drive housing.
The deviation in concentricity is more than ±1 mm?

The mixer shaft is damaged.
▶ Have the mixer shaft replaced before the next site use.

8. Remove the dial gauge.
➙ You have checked the concentricity of the mixer shaft.
4.6.3.2 Inspecting the accumulator
The following maintenance work information describes inspection of

the pretensioning pressure. In Germany, the maintenance intervals
are prescribed by the Industrial Health and Safety Ordinance [Be‐
triebssicherheitsverordnung (BetrSichV)].
Please note any applicable regulations in your country of use.
WARNING
Risk of injury
Risk of burning and impact from explosions due to incorrectly filling
the accumulator.
▶ Only fill the accumulator with nitrogen.

Maintenance

ter.

A subject expert for the inspection and filling of accumulators is

someone who has demonstrably been instructed in this activity by
an authorised inspector.
Prerequisites:
✓ The ambient temperature is 20 °C.
✓ The temperature of the hydraulic fluid is 20 °C.
The required pressures can be found in the machine measurement

record. The measurement record can be found in the documentation
binder in the “Technical data” tab.
Pressure Entry in the measurement re‐

cord
Accumulator charge pressure BP18
(see glossary)
Precharge pressure (see glos‐ BP19
sary)

2. Load the accumulator with hydraulic fluid until the pressure gauge
displays the maximum accumulator charge pressure.

Maintenance
⇒ The accumulator pump stops.

⇒ The accumulator dump valve remains energised, i.e. the accu‐
mulator pressure is not dumped.
⇒ The accumulator charge pressure is at least 85% of the value
in the measurement record.
4. Observe the pressure gauge while you slowly dump the accumu‐
lator charge pressure.
5. Read off the value at which the indicator falls suddenly.
⇒ Top up the accumulator if the value read off is less than 85%
of the precharge pressure.
Topping up the accumulator
WARNING
Risk of injury from hydraulic fluid shooting out
1. Relieve the pressure in the hydraulic system before starting
maintenance work.
2. Before starting maintenance work on the accumulator, dump
the accumulator charge pressure.
In Germany, the inspection periods and the persons authorised to top

up the accumulator depend on the category assigned according to
the Industrial Health and Safety Ordinance [Betriebssicherheitsver‐
ordnung (BetrSichV)] and on the maximum permissible pressure:
● Hydraulic fluids and nitrogen belong to the fluids in Group 2 in ac‐
cordance with Directive 2014/68/EU. Article 13 of Directive
2014/68/EU, in connection with Annex II, Diagram 2, applies for
the classification of the pressure equipment.
● The maximum permissible pressure (PS), the volume (V in litres)
and the classified category of the accumulator can be found in the
declaration of conformity for the accumulator (see the “Technical
Appendix” binder).
1. For additional information, please see the following table.

2. Please note the provisions for “inspection periods for recurring in‐
spections” that apply in your country.

Maintenance
Classification of the pressure Recurring inspection in accordance with Betr‐ Inspector

equipment SichV
External in‐ Internal in‐ Stability in‐
spection spection spection
Category I, category II - ○
Category III (PS ≤ 1 bar
Category III (PS > 1 bar 2 years 10 years * 10 years ●
Category IV
● ○ = to be carried out by subject experts.

● ● = to be carried out by an authorised supervision institution.
● - = no prescribed inspection period
● * = in accordance with BetrSichV, Appendix 5, Number 2:
For pressure equipment with gas cushions in hydraulic fluid sys‐
tems, recurring internal inspections must be carried out at the lat‐
est after 10 years, provided the liquids and gases used do not ex‐
ert any corrosive impact.
3. Provide the subject expert with the tools and devices necessary
for inspecting and filling pressure containers.
4.6.3.3 Lubricating the transfer tube
The following maintenance work information describes lubrication of

all lubrication points on the transfer tube in cases where you have no
centralised lubrication system or the centralised lubrication system
fails.

ter.


Maintenance

● Grease gun
Use a K2K grease in accordance with DIN 51502:1990, NLGI

Class 2.
1. Repair the centralised lubrication system immediately.
Figure 9: Transfer tube and plunger cylinder lubrication diagram
2. Lubricate the lubrication points once to three times daily if no oth‐

er interval is specified.
3. Apply grease until you can see it emerging.
4.6.3.4 Replacing the delivery pistons
Replace the wear parts if one of the following faults occurs:

● Severe wear is visible
● Concrete is seeping out

ter.


Maintenance

Damage to the delivery pistons must be rectified without delay.

Putzmeister accepts no warranty claims for damage to the ma‐
chine resulting from failure to properly observe the maintenance
regulations.
When replacing the delivery pistons, you must start up and shut down
the machine several times. The steps required to achieve this are de‐
tailed below.
Secure the working area. Place warning notices on blocked control

and setting devices.
▶ Execute all machine functions using the cable remote control.
Shutting down the machine
WARNING
Risk of death
1. Pressure in the hydraulic system may cause sudden machine
movements.
3. Before commencing work on the plant, check the pressure
gauge to ensure that the hydraulic fluid pressure in the plant
has been completely dumped.

2. Press the STOP BUTTON.
Starting up the machine

rectified.
2. Unlock any pressed EMERGENCY STOP BUTTONS.

Maintenance
Closing the stroke correction lines
Each drive cylinder stroke correction line has a ball valve (KEP) that
is fitted open (markings parallel to the line) ex works and is locked
against turning.
Figure 10: Stroke correction line open
Prerequisites:
✓ You have reduced the output to 50%.
✓ You have set the engine speed to approx. half the maximum value.
✓ You have shut down the machine.

Maintenance
Figure 11: As-fitted position of the guide washer
Item Designation
1 As-fitted position secured against rotation
2 Rotate position
You can carry out the following steps at the same time for both ball
valves.
1. Remove the bolt on the handle.

2. Remove the handle.
3. Lift up the guide washer, rotate it by 90° and refit it in the “Rotate”
mounting position.
4. Fit the handle.
5. Securely screw in the handle.
6. While the core pump is running, press and hold the “Change-
over” BUTTON until the core pump switches off.

Maintenance
Figure 12: Turning the handle
7. Close the BALL VALVE if both drive cylinders are no longer moving.
Once you have closed the ball valve, it may be that a drive cylinder
moves again briefly until both drive cylinders are finally at the me‐
chanical end position.

9. Release the CHANGE-OVER “button”.
➙ You have closed the stroke correction lines.
Replacing the delivery pistons
To replace the delivery pistons, you may work with the remote control
on the flatbed.

Maintenance
WARNING
Moving parts in the water box
Risk of crushing and injury by shearing when reaching into the wa‐
ter box
1. Switch off the machine before reaching into the water box.
2. Make sure that no one is working on the water box before
switching on the machine.
3. Maintenance work on the water box must only be carried out by
trained, qualified personnel.
1. Shut the machine down.

2. Remove the cover from the water box.
3. Drain off the water from the water box.
5. Move one drive piston to the end position.

⇒ The spacer flange is fully visible in the water box.
7. Remove the grille from the water box.
Figure 13: Piston setup
Item Designation
1 Piston rod flange
2 Fastening bolts
3 Retaining rings

Maintenance
Item Designation
4 Delivery piston
5 Spacer flange
8. Remove the fastening bolts.

9. Remove the retaining rings.
10. Remove the spacer flange.
11. Lever the delivery piston completely out of the delivery cylinder.
12. Remove the old delivery piston.
NOTICE
Material damage
The chrome layer of the delivery cylinder may be damaged.
▶ Do not use any hard objects or caustic cleaning agents to clean
the delivery cylinder.
13. Thoroughly clean the delivery piston edge at the end of the water
box.
14. Grease a new delivery piston heavily with acid-free grease
(e.g. petroleum jelly).
Figure 14: Position of the jacking bolts
Item Designation
1 Jacking bolts
15. Remove the protective caps from both jacking bolts.

Maintenance
16. Fit the new delivery piston using the two jacking bolts on the drive
piston.
17. Make sure that there are no loose parts in the water box.
18. Step away from the water box.
20. Slowly extend the drive piston.
⇒ The new delivery piston is pushed into the delivery cylinder.
⇒ The jacking bolts remain freely accessible.
22. Unscrew the jacking bolts.
23. Put on the protective caps.
25. Retract the drive piston.
⇒ The spacer flange fits between the delivery piston and the
drive piston.
27. Insert the spacer flange.
28. Put the retaining rings on the fastening bolts.
29. Fasten all fastening bolts on the delivery piston.
30. Fasten all fastening bolts on the drive piston.
31. Tighten the fastening bolts with the specified tightening torques.
⇒ You have replaced a delivery piston.
32. Fit the second delivery piston in the same way.
33. Open the stroke correction lines. (Opening the stroke correction
lines P. 4 — 44)
Opening the stroke correction lines
If the stroke correction lines are closed, it may no longer be possible

for the core pump to change over and it will become worn quicker.
Prerequisites:
✓ You have replaced both delivery pistons.
✓ The stroke correction lines are closed.

Maintenance
You can carry out the following steps at the same time for both ball
valves.
1. Open the BALL VALVE (KEP).

2. Remove the bolt on the handle.
3. Remove the handle.
Figure 15: Turning and securing the ball valve
4. Rotate the guide washer by 90° and fit it so that it is blocked.

5. Fit the handle.
6. Securely screw in the handle.
7. Replace the second delivery piston in the same way.
8. Make sure that you have opened both stroke correction lines.
9. Carry out a test run.
4.6.3.5 Measuring the wall thickness of the S transfer tube
The following maintenance work information describes measuring the

wall thickness of the S transfer tube. The maintenance intervals can
be found in the overview at the start of this chapter.

Maintenance
WARNING
Risk of injury
The S transfer tube could burst once it reaches a high delivery pres‐
sure if the wall thickness of the S transfer tube has decreased be‐
low the minimum dimension, particularly if a blockage has formed.
▶ Carry out regular wall thickness measurements in accordance
with the regulation.
WARNING
Risk of injury
If the wall thickness has fallen below its minimum value, conveyed
medium can spray out if cracks form in the S transfer tube.
1. Carry out maintenance on the S transfer tube at the regular
maintenance interval.
2. Carry out regular wall thickness measurements.
3. For two-layer pipes, carry out a visual inspection for wear in the
inner pipe.

ter.

● ( Measuring the wall thickness of a two-layer pipe P. 4 — 106)
● Wall thickness measuring device

parts list.

Maintenance
The S transfer tube is subject to constant wear. Measuring the wall

thickness is particularly important before starting on major con‐
tracts. You will obtain reliable results for your measurements if you
carry out the test with the measuring device recommended by
Putzmeister.
S transfer tube
The minimum wall thickness for the S transfer tube depends on the
maximum possible operating pressure. The S transfer tube is subjec‐
ted to greater load in the area of torque absorption (switching shaft –
S transfer tube).
Figure 16: X = Area subject to a high load
Operating pressure up to Guide value for wall thickness

130 bar
Area A 8-10 mm
Area B 6-8 mm
Measuring
1. Follow the instructions in the Operating Instructions for the meas‐

uring device.
2. Measure the wall thickness of the delivery line over the entire cir‐
cumference of the delivery pipe, not just at one point on the line.
3. Replace pipes and elbows as soon as the wall thickness has fall‐
en below the guide value.

Maintenance
Putzmeister accepts no liability if the wall thickness is less than the

minimum wall thickness.
As a rule, it is possible to continue pumping with an operating

pressure lower than that shown in the graph.
Due to dynamic loading during pumping, the delivery line is subjec‐

ted to different loads. There is no general method for calculating
the minimum wall thickness for this load, which depends on indi‐
vidual circumstances, meaning that the delivery line can also burst
at an operating pressure that is supposedly still permissible.
In the event of a blockage, the operating pressure can rise to

85 bar, which may mean that the wall thickness no longer suffices
and the delivery line bursts.
4.6.3.6 Replacing the transfer tube bearing
The following maintenance work information describes replacement

of the transfer tube bearing.

WARNING
Risk of death
The hydraulic system is pressurized. Sudden machine movements
may occur during operation.
2. Secure the machine against unauthorized or accidental starting
up.

Maintenance

ter.


parts list.
Use only suitable lifting equipment for lifting components.
Prerequisites:
✓ The machine is cleaned.
WARNING
Risk of death
movements.


Maintenance

rectified.
Dismantling the transfer tube bearing
The transfer tube is seated in the rear hopper wall with the transfer
tube bearing.
Item Designation
1 Pressure connection
2 Pressure flange
3 Hexagon nut
4 Hopper

2. Disconnect the delivery line from the pressure connection.
3. Open the grille and secure it.

Maintenance
4. Suspend the transfer tube from suitable lifting equipment.

5. Remove the lubrication lines from the transfer tube bearing.
6. Remove the nut from the pressure flange.
7. Remove the pressure flange.
8. Pull out the pressure connection and the transfer tube bearing.
9. Check the gasket set of the transfer tube bearing for wear.
Replace the gasket set if necessary.
Replacing the transfer tube bearing gasket set
Figure 17: Bending the grooved ring to make installation easy
The mounting position for the gasket set in the transfer tube bear‐
ing can be found in the corresponding spare parts sheet.
1. Grease the new gasket set.

2. Bend the grooved ring to make installation easier.
3. Insert the gasket set as shown on the spare parts sheet.
4. Clean the transfer tube bearing before refitting and grease the
seals.
5. Inspect the lubrication holes for proper functioning by connecting
the lubrication lines and pressing grease through the openings.

Maintenance
Assembling the transfer tube bearing
Item Designation
2 Pressure flange
3 Hexagon nut
4 Hopper
When fitting the transfer tube bearing, note the position of the lubri‐
cation openings.
1. Fit the transfer tube bearing and pressure connection onto the
transfer tube outlet.
2. Fit the pressure flange onto the pressure connection.
3. Securely screw in the pressure flange.
4.6.3.7 Replacing the switching shaft bearing
The maintenance intervals can be found in the overview at the start of

this chapter.
Replace the wear parts in the following cases:


Maintenance

ter.

● (Adjusting the S transfer tube P. 4 — 93)

parts list.

Maintenance
1 2 3 4 5 6 7 8 9 10
13 12 11
Figure 18: Overview of the switching shaft bearing
Item Designation
1 Pulling bore for ball cup
2 Ball cup
3 Hydraulic port
4 Plunger cylinder
5 Retaining plate
6 Retaining plate fastening bolts
7 Switch lever
8 Washer
9 Switching shaft
10 Hexagon nut
11 Switching shaft bearing
12 Fastening bolt for switching shaft bearing (covered)

Maintenance
WARNING
Risk of death
movements.

Removing the switching shaft bearing
NOTICE
The switching shaft of the transfer tube is mounted in the front wall of
the hopper in the switching shaft bearing.
Prerequisites:
✓ You have shut down the machine.

Maintenance
Figure 19: Retaining plate assembly
1. Remove any lubrication lines that may be present on the retaining

plate and on the switching shaft bearing.
2. Remove the fastening bolts on the retaining plate.
3. Remove the retaining plate.
4. Place an oil sump pan under the working area.
5. Place a container under the bulkhead union as well.
6. Remove the hydraulic hose that leads to the plunger cylinder
from the bulkhead union.
7. Catch the hydraulic fluid flowing out of the hydraulic line and hy‐
draulic hose.
8. Seal the hydraulic line with a plug.

Maintenance
Figure 20: Removing the locking plate
Item Designation
1 Plunger cylinder
2 Locking plate
3 Ball cup
4 Pulling bore
You can push a plunger cylinder on the piston side out of the ball
cup , as shown. If the ball cup is worn, you can screw a bolt into
the pulling bore for the ball cup and push out the plunger cylinder
with the ball cup.
9. Remove the locking plate .

10. Push back the plunger cylinder piston rod .
11. Remove the plunger cylinder with the hydraulic hose.
12. If required, remove the hydraulic hose from the plunger cylinder .
13. Catch the hydraulic fluid flowing out of the hydraulic hose.
14. Remove the second plunger cylinder in the same way.

Maintenance
Figure 21: Overview of the switch lever
Item Designation
1 Switch lever
2 Pulling bolt
15. Remove the hexagon nut and the washer from the switching
shaft.
16. Remove the O-ring from the switching shaft (if present).
17. Pull the switch lever from the switching shaft.
Figure 22: Fastening the switching shaft bearing
Item Designation
1 Fastening bolt
2 Pulling bore
two diagonally opposite each other
18. Suspend the transfer tube from suitable lifting equipment.

19. Unscrew the fastening bolt on the switching shaft bearing.

Maintenance
⇒ The switching shaft bearing is pushed out.

20. Check the gasket set of the switching shaft bearing for wear.
21. Replace the gasket set if necessary.
Replacing the switching shaft bearing gasket set
Figure 23: Removing the retaining ring
1. Remove the retaining ring.
Figure 24: Removing the old grooved ring
2. Remove the old gasket set.

3. Cut the rings open if necessary.

Maintenance
Figure 25: Inserting the new grooved ring
For the mounting position of the grooved ring in the flanged bear‐
ing, please refer to the accompanying spare parts sheet.
4. Clean the switching shaft bearing.

5. Grease the new gasket set.
6. Insert the gasket set.
7. If there is a friction bearing socket, check it and replace as re‐
quired.
8. Fit the retaining ring.

Maintenance
Replacing the switching shaft bearing wear sleeve and collared wash‐
er
Figure 26: Overview of switching shaft bearing wear sleeve
Item Designation
1 Switching shaft bearing wear sleeve
3 Collared washer
4 Bore
5 Tab
1. Bend the tab of the collared washer downwards.

2. Place the collared washer on the switching shaft bearing.
⇒ The tab is in the bore and thereby secured against twisting.
3. Slide the wear sleeve into the switching shaft bearing.
You can fit the switching shaft bearing.
Fitting the switching shaft bearing
Prerequisites:
✓ The intermediate ring and the spectacle wear plate are fitted.
✓ The thrust ring and the wear ring are fitted.
✓ The transfer tube bearing is fitted.

Maintenance
Preparing the switching shaft
Item Designation
2 Pressure flange
3 Hexagon nut
4 Hopper
1. Release the transfer tube bearing.

2. Move the flange of the transfer tube bearing approximately
20 mm away from the rear wall of the hopper.

Maintenance
Figure 27: Undoing the transfer tube bearing
Item Designation
1 Rear wall of the hopper
2 Stransfer tube bearing
3 no clearance = incorrect
3. Lift the transfer tube.
Figure 28: Lifting the transfer tube

Maintenance
Figure 29: Positioning the switching shaft
Item Designation
1 Bore: Rear wall of the hopper
2 Bore: Front wall of the hopper
3 Switching shaft
4. Position the switching shaft on the axis between the bore on the
rear wall of the hopper and the bore on the front wall of the hop‐
per.

Maintenance
⇒ The switching shaft and the bore on the front wall of the hop‐
per are concentric.
Figure 30: Switching shaft aligned concentrically
Item Designation
1 Bore on the front wall of the hopper
2 Switching shaft
5. When fitting the switching shaft bearing, note the position of the
lubrication openings.
6. Grease the inside of the wear sleeve and the outside of the
switching shaft bearing with “anti-seize agent AS 450 assembly
paste” or similar assembly grease.
7. Fit the complete switching shaft bearing onto the switching shaft.
8. Connect the centralised lubrication system to the switching shaft
bearing.

Maintenance
Figure 31: Setup of the switching drive
Item Designation
1 Switch lever
2 Switching shaft
4 Groove
5 Wear sleeve
6 Flattened tooth
9. Grease the teeth of the switch lever and the switching shaft with
“anti-seize agent AS 450 assembly paste” or similar assembly
grease.

Maintenance
Assembling the transfer tube bearing
Item Designation
2 Pressure flange
3 Hexagon nut
4 Hopper
▶ Secure the transfer tube bearing.

⇒ The transfer tube bearing is now touching the rear wall of the
hopper.

Maintenance
Mounting the switch lever
Figure 32: Fitting the switch lever
Item Designation
1 Switch lever
2 Switching shaft
3 Oring
4 Washer
5 Hexagon nut
The flattened tooth of the switching shaft must align with the centre of
the switch lever for the transfer tube to be in the correct position. The
centre of the switch lever may be marked with a line.
1. Place the switch lever on the switching shaft.
⇒ The flattened tooth of the switching shaft is aligned with the
centre of the switch lever.
⇒ The switch lever sits in the groove of the wear sleeve.
The switch lever does not sit in the groove of the wear sleeve?
▶ Turn the switch lever until you can slide it into the groove of
the wear sleeve.
2. Place the washer on the switching shaft.

3. Screw the hexagon nut on the switching shaft.

Maintenance
4. Lubricate the switching shaft bearing using the centralised lubri‐

cation system/grease gun.
5. Fit the plunger cylinders.
6. Replace the lock washers of the fastening bolts on the retaining
plate with new ones.
7. Fit the retaining plate .
Figure 33: Retaining plate assembly
8. Fit the fastening bolts on the retaining plate.
Vent the hydraulic system after complete assembly if you have re‐
moved the hydraulic hoses from the plunger cylinders.
Slowly start the pump and switch the transfer tube over slowly sev‐
eral times.
Adjust the transfer tube so that it switches over correctly.

(Adjusting the S transfer tube P. 4 — 93)
4.6.3.8 Replacing the S transfer tube

of the S transfer tube. The maintenance intervals can be found in the
overview at the start of this chapter.


Maintenance
We recommend that the slewing locking mechanism also be re‐

placed when the S transfer tube is replaced. Practical experience
has shown that the toothing on the switching shaft and that on the
slewing locking mechanism wear together as a result of the forces
generated during switchover. Damage may be caused by an im‐
precise fit if only one component is replaced. (Replacing the
switching shaft bearing P. 4 — 52)

ter.

● (Replacing the transfer tube bearing P. 4 — 48)
● (Replacing the switching shaft bearing P. 4 — 52)
● (Replacing the transfer tube wear sleeve P. 4 — 84)
● (Replacing the thrust ring and wear ring P. 4 — 90)
● (Measuring the wall thickness of the S transfer tube P. 4 — 45)


parts list.
WARNING
Risk of death
up.

Maintenance
Prerequisites:
The machine must be shut down. The steps required to achieve this
are detailed below. Use the remote control here.
WARNING
Risk of death
movements.


rectified.

Maintenance
S transfer tube variants
Figure 34: S transfer tubes
Item Designation
1 S transfer tube with bolted switching shaft
2 S transfer tube with welded switching shaft
Whichever variant of S transfer tube is fitted, the recommended pro‐

cedure for dismantling is as described below.
Dismantling the S transfer tube
Prerequisites:
Replace the S transfer tube if the wall thickness has fallen below the
minimum. (Measuring the wall thickness of the S transfer tube
P. 4 — 45) and ( Measuring the wall thickness of a two-layer pipe
P. 4 — 106)

2. Attach suitable lifting equipment to the S transfer tube.
3. Remove the transfer tube bearing. (Replacing the transfer tube
bearing P. 4 — 48)
4. Remove the switching shaft bearing (flanged bearing). (Replacing
the switching shaft bearing P. 4 — 52)

Maintenance
Figure 35: Removing the mixer shaft
5. Remove the mixer shaft.
Figure 36: Lifting out the S transfer tube
6. Unbolt the scratch bar from the bottom of the S transfer tube.
7. Push the S transfer tube forwards until the transfer tube outlet is
uncovered.
8. Lift the S transfer tube outlet opening first upwards and out.
If just the wear sleeve is heavily worn, you can also replace just
the wear sleeve and then refit the S transfer tube. (Replacing the
transfer tube wear sleeve P. 4 — 84)

Maintenance
9. Fit the new S transfer tube. To do this, proceed in the reverse or‐
der to removal.
10. Fit a new thrust ring and a new wear ring. (Replacing the thrust
ring and wear ring P. 4 — 90)
11. Fit the switching shaft bearing (flanged bearing). (Replacing the
switching shaft bearing P. 4 — 52)
12. Fit the transfer tube bearing. (Replacing the transfer tube bearing
P. 4 — 48)
13. Adjust the S transfer tube so that it switches correctly. (Adjusting
the S transfer tube P. 4 — 93)
4.6.3.9 Replacing the spectacle wear plate

of the spectacle wear plate. The maintenance intervals can be found
in the overview at the start of this chapter.

WARNING
Risk of death
up.

ter.


Maintenance
● (Replacing the thrust ring and wear ring P. 4 — 90)


● No further special tools are required.
You should request special fitting instructions from us if you have a

spectacle wear plate made from a special material (e.g. carbide,
white cast iron, ceramics).

parts list.
Prerequisites:
WARNING
Risk of death
movements.


rectified.

Maintenance

Removing the spectacle wear plate
1 2 3 4 1
5 5 5
Figure 37: Spectacle wear plate setup
Item Designation
1 Plunger cylinder
2 Switch lever
3 Switching shaft
4 Hexagon nut
5 Fastening bolts for spectacle wear plate

2. Loosen the hexagon nut on the switching shaft.

Maintenance
3. Remove the plunger cylinders. (Replacing the switching shaft

bearing P. 4 — 52)
If there is not enough space available for assembly, you can pull
the pressure connection towards the back.
4. Push the transfer tube away from the spectacle wear plate.
Figure 38: Pushing the transfer tube to one side
5. Unscrew the eight fastening bolts for the spectacle wear plate.
6. Remove the spectacle wear plate from the hopper.

Maintenance
Replacing the intermediate rings
Figure 39: Intermediate ring setup
Item Designation
1 Transition liner
2 Intermediate ring
3 Screw plug
4 Lubrication nipple
5 Grease gun
1. Using a plastic-faced hammer, strike the old intermediate ring a

few times from the front.
⇒ Any concrete and grout residue is loosened.

Maintenance
2. Replace the screw plug on the underside of the transition liner

with the lubrication nipple from the accessories.
3. Connect a grease gun to the lubrication nipple.
4. Pump grease into the lubrication nipple until the intermediate ring
is pushed out.
Figure 40: Leaving the pulling bore open
5. Remove the lubrication nipple.

⇒ This means that no air cushion can be created behind the new
intermediate ring as it is inserted, thus making it easier to fit
the intermediate ring.
6. Clean the mounting surface thoroughly.
7. Remove all concrete and grout residue.

Maintenance
Figure 41: Overview of O-rings
Item Designation
1 Intermediate ring
2 O-rings
3 O-rings for sealing the delivery cylinder
4 Transition liner
8. Stretch the O-rings over the mounting surface of the new inter‐
mediate ring.
9. Grease the mounting surface of the new intermediate ring.
10. Insert the new intermediate ring into the transition liner.
11. Use a plastic-faced hammer to tap the intermediate ring all the
way into the transition liner.
12. Replace the second intermediate ring in the same way.

Maintenance
Figure 42: Inserting the O-ring
13. Insert an O-ring in the groove on the front of each intermediate

ring.

Maintenance
Fitting the spectacle wear plate
1 1
Figure 43: Setup for using the spectacle wear plate
Item Designation
1 Fastening bolts on the left and right
3 Fastening bolts at the top and bottom
4 Intermediate ring
5 Oring
6 Hopper wall
7 Clearance
1. Fit the new spectacle wear plate.

2. Using the fastening bolts on the left and right, screw on the new
spectacle wear plate until it is finger-tight.

Maintenance
If you have a ceramic spectacle wear plate, please contact our Af‐
ter Sales department to enquire about the tightening torques.
3. Using the fastening bolts at the top and bottom, screw on the
spectacle wear plate to the appropriate tightening torque.
Take care to ensure that the spectacle wear plate does not be‐
come warped.
4. Using the fastening bolts on the left and right, screw on the spec‐
tacle wear plate to the appropriate tightening torque.
Figure 44: Sealing the pulling bore
The pulling bores must be sealed so that no dirt can enter.

Maintenance
NOTICE
Damage to the spectacle wear plate
If there are lubrication nipples in the pulling bores and these are al‐
so lubricated when lubricating the machine, the intermediate rings
will be pushed out. This would cause the spectacle wear plate to
become warped.
▶ Only use the screw plugs to seal the pulling bores.
5. After inserting the new intermediate rings and spectacle wear

plate, seal the pulling bores again using the screw plugs.
6. Replace the thrust ring and wear ring.
⇒ (Replacing the thrust ring and wear ring P. 4 — 90)
7. Fit the transfer tube bearing.
⇒ (Assembling the transfer tube bearing P. 4 — 52)
8. Fit the plunger cylinders.
⇒ (Replacing the switching shaft bearing P. 4 — 52)
9. Adjust the transfer tube so that it switches through correctly.

⇒ (Adjusting the S transfer tube P. 4 — 93)
4.6.3.10 Replacing the transfer tube wear sleeve

of the transfer tube wear sleeve. The maintenance intervals can be
found in the overview at the start of this chapter.


Maintenance
WARNING
Risk of death
up.

ter.



parts list.

Maintenance
WARNING
Risk of death
movements.


rectified.
Removing the wear sleeve
CAUTION
Risk of injury
Risk of burning when heating and pushing on the new wear sleeve.
▶ Wear suitable protective equipment.

Maintenance
If just the wear sleeve is heavily worn, you can replace it without hav‐
ing to replace the transfer tube. You do not have to remove the trans‐
fer tube to do this.

2. Remove the transfer tube bearing. (Replacing the transfer tube
bearing P. 4 — 48).
3. Loosen the hexagon nut on the switching shaft and the clamping
bolts on the slewing locking mechanism. (Replacing the switching
shaft bearing P. 4 — 52).
Removal when the transfer tube is fitted
Figure 45: Removing the wear sleeve
Item Designation
1 Welds
2 Transfer tube outlet
3 Wear sleeve
If the transfer tube has been fitted, proceed as follows:
1. Weld a metal pin onto the wear sleeve.

Maintenance
2. Carefully cut open the welding points (1) on the front between the
transfer tube outlet (2) and the wear sleeve (3) using an angle
grinder. Do not damage the transfer tube when doing so.
3. Heat up the wear sleeve (3) evenly to approx. 140 °C.
4. Strike the metal pin with a hammer.
⇒ The wear sleeve will come loose.
5. Remove the wear sleeve (3).
Removal when the transfer tube is removed
If the transfer tube has been removed, proceed as follows:
1. Carefully cut open the welding points (1) on the front between the
transfer tube outlet (2) and the wear sleeve (3) using an angle
grinder. Do not damage the transfer tube when doing so.
2. Heat up the wear sleeve evenly to approx. 140 °C.
3. Cut open the wear sleeve (3) carefully using an angle grinder. Do
not damage the transfer tube when doing so.
4. Remove the wear sleeve (3).

Maintenance
Fitting the wear sleeve
Figure 46: Fitting the wear sleeve
Item Designation
1 Wear sleeve
2 Transfer tube outlet
The wear sleeve (1) is chrome-plated, and therefore must not be

heated unevenly or to too high a temperature.
1. Heat up the new wear sleeve (1) evenly to approx. 140 °C.
2. Place the heated wear sleeve (1) over the transfer tube outlet (2),
and let the wear sleeve (1) cool.
3. Evenly apply four weld points on the front between the wear
sleeve (1) and transfer tube outlet (2).
4. Grind the four weld points so that they are flush.
P. 4 — 48).
6. Tighten the hexagon nut on the switching shaft and the clamping
bolts on the slewing locking mechanism. (Replacing the switching
shaft bearing P. 4 — 52).

Maintenance
4.6.3.11 Replacing the thrust ring and wear ring

of the thrust ring and wear ring of the S transfer tube. The mainte‐
nance intervals can be found in the overview at the start of this chap‐
ter.

WARNING
Risk of death
up.

ter.

● (Replacing the spectacle wear plate P. 4 — 74)


parts list.

Maintenance
Prerequisites:
WARNING
Risk of death
movements.


rectified.
Removing the thrust ring and wear ring

2. Remove the transfer tube bearing.

Maintenance
⇒ (Replacing the transfer tube bearing P. 4 — 48)
3. Loosen the hexagon nut on the switching shaft and the clamping
bolts on the slewing locking mechanism.
⇒ (Replacing the switching shaft bearing P. 4 — 52)
4. Check the spectacle wear plate and replace it if required.
⇒ (Replacing the spectacle wear plate P. 4 — 74)
Figure 47: Thrust ring and wear ring
Item Designation
1 Thrust ring
2 Wear ring
5. Remove the old wear ring (2) and the old thrust ring (1).
Fitting the thrust ring and wear ring
1. Clean the thrust ring seat (1) thoroughly.

2. Remove the dirt and concrete residue from the retainer.
3. Insert the new thrust ring (1) and new wear ring (2) into the S
transfer tube.
P. 4 — 48)
5. Adjust the S transfer tube. (Adjusting the S transfer tube
P. 4 — 93)

Maintenance
4.6.3.12 Adjusting the S transfer tube
The following maintenance work information describes setting of the

S transfer tube.
● Pretensioning the S transfer tube.
● Adjust the switching overlap between the wear ring and spectacle
wear plate on the S transfer tube.

WARNING
Risk of death
up.

ter.


parts list.
Prerequisites:

Maintenance
WARNING
Risk of death
movements.


rectified.

Maintenance
Prestressing the S transfer tube
Figure 48: Hopper area setup
Item Designation
2 Wear ring
3 S transfer tube
4 Thrust ring
5 Gap
6 Hexagon nut
7 Retaining plate
8 Slewing locking mechanism
Ensure that the thrust ring (4) does not become damaged during
injection.
2. Tighten the hexagon nut (6) on the switching shaft until the wear
ring (2) is touching the spectacle wear plate (1).

Maintenance
Between the S transfer tube (3) and wear ring (2), a gap (5) must
be retained so that the S transfer tube (3) switches over correctly.
3. Check all sides to ensure that the wear ring (2) is touching the
spectacle wear plate (1).
4. Slowly tighten the hexagon nut (6) by half a revolution.
⇒ The thrust ring (4) is pretensioned by 1.5 mm.
⇒ The gap (5) between the S transfer tube (3) and wear ring (2)
is set.
5. Ensure that for re-attaching the retaining plate (7) one surface of
the hexagon nut (6) is horizontal at the top.
6. Fit the retaining plate (7).
7. Check that all covers and other safety equipment have been refit‐
ted and are fully functional.
Setting the switching overlap
The switching overlap is set optimally when the wear ring is cen‐
tred on each respective hole in the spectacle wear plate in both
switch positions of the transfer tube.
Spectacle wear plate with wear ring
Figure 49: Extended plunger cylinder
2. Allow the transfer tube to switch over once.

4. Use a felt tip pen or oil chalk to mark the position of the wear ring
on the spectacle wear plate.
6. Allow the transfer tube to switch over once.

Maintenance
Figure 50: Spectacle wear plate
Item Designation
1 Marking on the spectacle wear plate
Figure 51: Swing angle variants
Item Designation
1 Swing angle too great
2 Swing angle too small
3 Optimum swing angle
8. Determine to which side and by how many millimetres the drawn

circle has moved in relation to the circle on the spectacle wear
plate.

Maintenance
Figure 52: Plunger cylinder with packing washer
Item Designation
1 Plunger cylinder (switch cylinder)
2 Ball cup
3 Packing washer
9. Replace the packing washer behind the ball cup on the right-hand
plunger cylinder with a thicker or thinner one as required in order
to correct the left-hand switching overlap. The right-hand switch‐
ing overlap is corrected on the left-hand side in the same way.

Maintenance
Spectacle wear plate with example markings
Figure 53: Various packing washers
Item Designation
1 Packing washer too thin
2 Packing washer too thick
3 Optimum packing washer
To reduce the swing angle of the transfer tube by 4 mm, the integra‐
ted packing washer must be replaced with one that is 2 mm thicker.
To increase the swing angle of the transfer tube by 4 mm, the integra‐
ted packing washer must be replaced with one that is 2 mm thinner.

Maintenance
Figure 54: Plunger cylinder with locking plate
Item Designation
1 Plunger cylinder (switch cylinder)
2 Locking plate
1. Disassemble the locking plate from the extended plunger cylin‐

der .
Figure 55: Removing the plunger cylinders
2. Push the piston of the extended plunger cylinder back a little and
remove the plunger cylinder with the hydraulic hoses.
▶ Or screw a bolt into the jacking bore for the ball cups and press
the plunger cylinders out with the ball cups.

Maintenance
Figure 56: Plunger cylinder ball cup
Item Designation
1 Ball cup
2 Packing washer
3. Remove the ball cup.

4. Remove the packing washer.
NOTICE
Material damage
▶ Do not place any packing washers into the slewing locking
mechanism, as doing so may cause the plunger cylinder to run
onto the edge of the ball cup. This may cause the ball cup to
break.
5. Fit a thicker or thinner packing washer, as required, with the ball

cup.
6. Fit the plunger cylinder and locking plate.
8. Allow the transfer tube to switch over a few times.
9. Stop when the transfer tube is on the side of as the yet unmarked
wear plate.
11. Check and correct the switching overlap of the other wear plate
side.

Maintenance
4.6.4 Delivery line
4.6.4.1 Measuring the wall thickness of the delivery line

wall thickness of delivery lines. The maintenance intervals can be
found in the overview at the start of this chapter.
WARNING
Risk of injury caused by the delivery line exploding
The delivery line can burst once it reaches a high delivery pressure
if the wall thickness of the delivery line has decreased below the
minimum dimension, particularly if a blockage has formed.
▶ Carry out regular wall thickness measurements in accordance
with the regulation.
WARNING
Risk of injury
If the wall thickness has fallen below its minimum value, conveyed
medium can spray out if cracks form in the delivery line.
1. Maintain the delivery line at the regular maintenance interval.
2. Carry out regular wall thickness measurements.
3. For two-layer pipes, carry out a visual inspection for wear in the
inner pipe.

ter.

● Wall thickness measuring device

Maintenance

parts list.
Delivery lines are subject to constant wear. Measuring the wall

thickness is particularly important before starting on major con‐
tracts. You will obtain reliable results for your measurements if you
carry out the test with the measuring device recommended by
Putzmeister.
Only tap the delivery line with a piece of hardwood (hammer han‐
dle). Otherwise, dents may be created and these will lead to more
rapid wear. Moreover, the hardened layer of delivery pipes that are
highly resistant to wear can peel off on the inside. The delivery
pipe can burst at points that have suffered heavy wear.
Figure 57: Tap the delivery line with a hammer handle
Straight delivery pipes
1. Regularly turn straight delivery pipes through 120° to achieve

even wear.
2. For the minimum wall thickness of a straight delivery pipe, see
the wall thickness diagram below.
Elbows
1. Regularly turn the elbows through 180° to achieve even wear.
The wear on the outer radius of an elbow is greater than on the inter‐
nal radius or on straight pipes.
2. Measurements on the outer radii of elbows must therefore be car‐
ried out with particular care.
3. The minimum wall thickness for elbows is shown in the wall thick‐
ness graph below.

Maintenance
Figure 58: Rotate delivery pipes and bends regularly

Maintenance
Measuring
Figure 59: Minimum wall thickness as a function of operating pressure
Item Designation
1 High pressure
2 Maximum delivery pressure

Maintenance
1. Follow the instructions in the Operating Instructions for the meas‐

uring device.
2. Measure the wall thickness of the delivery line over the entire cir‐
cumference of the delivery pipe, not just at one point on the line.
3. The minimum wall thickness is shown in the wall thickness graph.
4. Replace delivery pipes and elbows as soon as the wall thickness
has reached the value for the minimum wall thickness.
Putzmeister accepts no liability if the wall thickness is less than the

minimum wall thickness.
As a rule it is possible to continue pumping with an operating pres‐

sure lower than that shown in the graph.
Due to dynamic loading during pumping, the delivery line is subjec‐

ted to different loads. There is no general method for calculating
the minimum wall thickness for this load, which depends on indi‐
vidual circumstances, meaning that the delivery line can also burst
at an operating pressure that is assumed to be permissible.
In the event of a blockage, the operating pressure can rise to

85 bar, which may mean that the wall thickness no longer suffices
and the delivery line bursts.
4.6.4.2 Measuring the wall thickness of a two-layer pipe

wall thickness of two-layer delivery lines. The maintenance intervals
can be found in the overview at the start of this chapter.

Maintenance
WARNING
Risk of death
Concrete can escape from the delivery line if it is pressurized. The
delivery line may be pressurized even when the concrete pump is
switched off.
1. Do not open the delivery line if it is still pressurized.
2. Do not tap the delivery line if it is still pressurized.
3. Draw the concrete back and depressurize the delivery line be‐
fore opening it.
4. Never bend over the delivery line coupling directly when you
are working.
5. Open the delivery line carefully, even if you cannot read off any
delivery pressure on the screen.

ter.

● Wall thickness measuring device material number 454460
Figure 60: Wall thickness measuring device

Maintenance
Observe all safety instructions in the machine-specific Operating

Instructions and in the Safety manual.
Inspecting two-layer delivery pipes and delivery line elbows
No. Model Minimum (mm)

DN 125 up to P1 P2
85 bar
Twin Pipe Twin Cast

1.1 Delivery line 7.1 + 3.6 4.1 3.6
elbow
1.2 7.0 + 2.0 7.0 3.0
2.1 Delivery pipe 2.5 + 2.0 2.5 3.3
2.2 2.5 + 2.0 2.5 4.9
2.3 5.6 + 3.0 3.7 3.7
2.4 5.6 + 3.0 3.7 3.1
Table 2: Minimum dimension for the wall thickness of two-layer delivery pipes and
elbows

Maintenance
1.1 - 1.2 Elbows

Measuring point P1/P2 mini‐
mum dimension (see table)
2.1 - 2.4 Delivery pipe

Measuring point P1/P2 mini‐
mum dimension (see table)
Table 3: Extract from Esser Service Manual - EM 070190, see Technical Appendix
Proceed as follows to check the two-layer delivery pipes and elbows

(DN 125, max. delivery pressure 85 bar):
1. Carry out a visual inspection on cracks.

2. If cracks form, replace the pipes/elbows.
3. Measure the wall thickness at measuring point P1 and measuring
point P2.
4. Replace the pipes/elbows if the value has fallen below the mini‐
mum dimension. Take note of the values in the table. (Minimum
dimension for the wall thickness of two-layer delivery pipes and
elbows P. 4 — 108)

Index
Index
In this chapter, you will find the most important keywords and the number(s) of the page(s) on which they
appear. This index of key words is in alphabetical order.
A Electrical power P. 2 — 7
Adjusting the S transfer tube P. 4 — 93 Electrical system P. 4 — 20
Assembling the transfer tube bearing P. 4 — 52, 4 — 67 Emergency operation of the core pump P. 3 — 5
Auxiliary devices P. 4 — 5 Exclusion of liability P. 2 — 3
Exhaust fumes P. 2 — 10
B
Basic principle P. 2 — 3 F
Filling the hydraulic fluid reservoir P. 4 — 24
C
Fitting the spectacle wear plate P. 4 — 82
Carrying out function checks P. 4 — 24
Fitting the switching shaft bearing P. 4 — 61
Carrying out visual checks P. 4 — 19
Fitting the thrust ring and wear ring P. 4 — 92
Changing the hydraulic fluid in the hydraulic fluid reser‐
Fitting the wear sleeve P. 4 — 89
voir P. 4 — 21
Fitting threaded unions P. 4 — 9
Checking hydraulic hose lines for leaks P. 4 — 26
Fitting WALFORMplus threaded unions P. 4 — 12
Checking the concentricity of the mixer shaft P. 4 — 32
Fluid analysis P. 4 — 21
Checking the threaded unions P. 4 — 28
Foreword P. 1 — 3
Closing the stroke correction lines P. 4 — 39
Functional fluids P. 2 — 11, 4 — 13
Core pump P. 4 — 32
D G
General P. 2 — 7, 2 — 8, 4 — 19
Delivery line P. 4 — 102
General tightening torques P. 4 — 8
Dismantling the S transfer tube P. 4 — 72
Greases P. 4 — 18
Dismantling the transfer tube bearing P. 4 — 50
Guide to the Service Instructions P. 1 — 1
Disposal of the machine P. 2 — 12
Draining the hydraulic fluid P. 4 — 23

H
Hydraulic fluid reservoir capacity P. 4 — 15
E
Hydraulic fluids P. 4 — 13
Elbows P. 4 — 103
Hydraulics P. 4 — 20
Electrical components P. 2 — 8
214490294_2021-12-20_en Service Instructions C—1

Index
Hydraulic system P. 4 — 20 O
Hydraulic systems P. 2 — 8 Opening the stroke correction lines P. 4 — 44
I P
Icons and symbols P. 1 — 4 Personal protective equipment P. 4 — 5
Inspecting the accumulator P. 4 — 33 Personnel requirements P. 4 — 5
Inspecting two-layer delivery pipes and delivery line el‐ Power at the construction site P. 2 — 8
bows P. 4 — 108
Preparing for recovery P. 3 — 3
Preparing the replacement of the hydraulic fluid filters

L
P. 4 — 30
Layout of warning notices P. 1 — 5
Preparing the switching shaft P. 4 — 62
Level of contaminant P. 4 — 15
Prestressing the S transfer tube P. 4 — 95
Lubricant analysis P. 4 — 17
Protective and safety equipment P. 2 — 6
Lubricant recommendation P. 4 — 17
Lubricating the transfer tube P. 4 — 36 R

Reassembly of WALFORMplus threaded unions
M P. 4 — 10
Maintaining the hydraulic lines P. 4 — 25 Recovery with onboard equipment P. 3 — 3
Maintenance P. 4 — 1 Removal when the transfer tube is fitted P. 4 — 87
Maintenance intervals P. 4 — 3 Removal when the transfer tube is removed P. 4 — 88
Maintenance work P. 4 — 19 Removing the spectacle wear plate P. 4 — 76
Measuring P. 4 — 47, 4 — 105 Removing the switching shaft bearing P. 4 — 55
Measuring the wall thickness of a two-layer pipe Removing the thrust ring and wear ring P. 4 — 91
P. 4 — 106
Removing the wear sleeve P. 4 — 86
Measuring the wall thickness of the delivery line
Replacing hydraulic hose lines P. 4 — 27
P. 4 — 102
Replacing hydraulic hoses P. 2 — 10
Measuring the wall thickness of the S transfer tube
P. 4 — 45 Replacing the delivery pistons P. 4 — 37, 4 — 41
Mounting the switch lever P. 4 — 68 Replacing the hydraulic fluid P. 4 — 20
Replacing the hydraulic fluid filter P. 4 — 29

N
Replacing the intermediate rings P. 4 — 78
Noise emissions P. 2 — 10
Replacing the pressure filter P. 4 — 30
Notes on fluid changes P. 4 — 16
Replacing the spectacle wear plate P. 4 — 74
Notes on mixing hydraulic fluids P. 4 — 16
C—2 Service Instructions 214490294_2021-12-20_en

Index
Replacing the S transfer tube P. 4 — 69 Straight delivery pipes P. 4 — 103
Replacing the switching shaft bearing P. 4 — 52 S transfer tube P. 4 — 47
Replacing the switching shaft bearing gasket set S transfer tube variants P. 4 — 72
P. 4 — 59
Replacing the switching shaft bearing wear sleeve and T
collared washer P. 4 — 61 Tightening torques P. 4 — 11
Replacing the thrust ring and wear ring P. 4 — 90 Topping up the accumulator P. 4 — 35
Replacing the transfer tube bearing P. 4 — 48 Transmission fluid P. 4 — 18
Replacing the transfer tube bearing gasket set
P. 4 — 51 W
Replacing the transfer tube wear sleeve P. 4 — 84 Welding P. 2 — 4
Requirements for special work P. 2 — 3 Working on the placing boom P. 2 — 5
Residual risks P. 4 — 6
Residual risks during maintenance, inspection and re‐

pair work P. 4 — 5
Restoring the operating state P. 4 — 24
S
Safety regulations P. 2 — 1
Safetyrelevant components P. 2 — 6
Set screws and nuts P. 4 — 9
Setting the switching overlap P. 4 — 96
Setting up the pump control system P. 3 — 4
Shutting down the machine P. 4 — 38, 4 — 49, 4 — 55,

4 — 71, 4 — 75, 4 — 86, 4 — 91, 4 — 94
Software P. 2 — 6
Special operating modes P. 3 — 1
Specifications for bolted connections P. 4 — 8
Spectacle wear plate with example markings P. 4 — 99
Spectacle wear plate with wear ring P. 4 — 96
Starting up the machine P. 4 — 38, 4 — 50, 4 — 71,

4 — 75, 4 — 86, 4 — 91, 4 — 94
Storage of lubricants P. 4 — 17
214490294_2021-12-20_en Service Instructions C—3

C—4 Service Instructions 214490294_2021-12-20_en

Sect. 2 Operating Instructions 2106T5571

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Sect. 2 Operating Instructions 2106T5571

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Operating Instructions

for machine operator and maintenance staff

Stationary concrete pump BSA 1005 D4F

Machine no. 2106T5571

España Putzmeister Ibérica S.A. +34−91−428 81 00 recepcion@putzmeister.es

South Putzmeister S.A. (Pty) Ltd. +27−11−794−37 90 pmsa@icon.co.za

Japan Putzmeister Japan Co. Ltd. +81-476-36-8907 info@putzmeister.jp

Korea Putzmeister Korea Co. Ltd. +82−31−433−4541 putzmstr@chollian.net

214490294_2021-12-20_en Operating Instructions

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

1.2 Icons and symbols .......................................................................................................... 1 —4

2 Safety regulations ................................................................... 2—1

2.2 Designated use ............................................................................................................... 2 — 10

2.3 Improper use ................................................................................................................... 2 — 12

214490294_2021-12-20_en Operating Instructions A—1

2.3.10 Accessories and attachments ......................................................................................... 2 — 15

2.4 Exclusion of liability ......................................................................................................... 2 — 16

2.5 Personnel ........................................................................................................................ 2 — 16

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

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

2.8 Before working with the machine .................................................................................... 2 — 21

2.9 Danger due to high voltage ............................................................................................. 2 — 22

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

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

2.12 Placing booms ................................................................................................................. 2 — 33

A—2 Operating Instructions 214490294_2021-12-20_en

2.12.5 Procedure in storms ........................................................................................................ 2 — 36

2.13 Delivery line systems ...................................................................................................... 2 — 37

2.14 Pumping operations ........................................................................................................ 2 — 40

2.15 Cleaning .......................................................................................................................... 2 — 42

3 General technical description ................................................. 3—1

3.2 Safety equipment ............................................................................................................ 3 —5

3.3 General conditions for using the machine ....................................................................... 3 — 17

3.4 Machine rating plate ........................................................................................................ 3 — 19

214490294_2021-12-20_en Operating Instructions A—3

3.5 Sound pressure level/sound power level ........................................................................ 3 — 20

3.6 Electromagnetic compatibility (EMC) .............................................................................. 3 — 20

3.7 Putzmeister Connected Services .................................................................................... 3 — 21

3.8 Exhaust after treatment ................................................................................................... 3 — 21

3.9 Colour definition – LEDs in the button ............................................................................. 3 — 24

3.10 Control cabinet ................................................................................................................ 3 — 25

3.11 Core pump operating panel ............................................................................................. 3 — 26

3.12 Display ............................................................................................................................ 3 — 28

3.13 Software .......................................................................................................................... 3 — 29

3.14 Cable remote control ....................................................................................................... 3 — 45

3.15 Core pump ...................................................................................................................... 3 — 48

3.16 Centralised lubrication system ........................................................................................ 3 — 60

A—4 Operating Instructions 214490294_2021-12-20_en

3.16.3 Maintaining the centralised lubrication system ................................................................ 3 — 61

4 Transport, support and connection ......................................... 4—1

4.2 Supporting the machine .................................................................................................. 4 —5

5 Operation ................................................................................ 5—1

5.2 Starting up ....................................................................................................................... 5 —3

5.3 Checking the functions .................................................................................................... 5 —9

5.4 Hand signals for pumping operations .............................................................................. 5 — 16

5.5 Filling the water box ........................................................................................................ 5 — 19

5.6 Pumping .......................................................................................................................... 5 — 20

214490294_2021-12-20_en Operating Instructions A—5

5.6.3 Damping valve ................................................................................................................ 5 — 21

5.7 Cleaning .......................................................................................................................... 5 — 30

5.8 Storing the machine ........................................................................................................ 5 — 59

Glossary .................................................................................. B—1

Abbreviations and technical terms .................................................................................. B — 11

A—6 Operating Instructions 214490294_2021-12-20_en