Beruflich Dokumente
Kultur Dokumente
2021-08-09
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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
Table of contents
Index ........................................................................................ C —1
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.
1.1 Foreword
These Operating Instructions aim to help you to familiarise yourself
with the machine and make use of its intended applications.
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.
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)
Icon/symbol/ Meaning
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.
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
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
Indicates a dangerous situation in which an accident resulting in se‐
rious or fatal injuries may occur.
▶ After identifying the risk, instructions are set out which are inten‐
ded to avoid or remedy the risk.
CAUTION
There is a risk of injury to the entire body, however there is no risk
of serious or fatal injuries.
▶ After identifying the risk, instructions are set out which are inten‐
ded to avoid or remedy the risk.
NOTICE
Risk of damage to the machine. There is no risk of injury.
▶ After identifying the risk, instructions are set out which are inten‐
ded to avoid or remedy the risk.
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.
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)
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.
Arm assembly is a synonym for placing boom and can be used inter‐
changeably.
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.
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.
For the purposes of this Safety Manual, truck mixers are defined as
vehicles with mixing equipment for transporting concrete.
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.
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
2.1.10 Operator
2.1.12 Hoseman
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.
2.1.18 Maintenance
Figure 1: Example
Figure 2: Example
The place of work is the area in which people must remain in order to
carry out the work.
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.
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.
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.
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 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.
The machine operator must stop work immediately and press the
EMERGENCY STOP button if an unauthorised person enters the
danger zone.
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.
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
Hopper
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.
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.
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.
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.
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.
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)
During pumping operations, the end hose must not be moved back‐
wards beyond the vertical axis of rotation of the placing boom.
You are not allowed to carry out your own changes to the machine.
Changes must always be approved by the manufacturer.
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
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.
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.
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).
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.
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)
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)
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)
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:
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.
2.9.3 Clearances
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.
If, despite all precautions, a flash over occurs, stay calm and do not
move (potential differential) or touch anything.
If you have any further questions about earthing the machine, please
contact site management or the operator of the machine.
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.
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.
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.
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.
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 corner bearing load is stated on each support leg. This value
must always be legible.
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‐
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.
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.
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.
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
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.
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.).
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‐
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.
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.
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.
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)
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 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.
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.
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.
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.
Delivery lines, delivery hoses, end hoses and couplings must be se‐
curely fastened and secured to prevent spontaneous opening.
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.
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.
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.
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.
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.
2.14.2 Safety
Refrain from any procedures that may impair the stability of the ma‐
chine or are prejudicial to safety in any other way.
You must always carry the remote control on your person when 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.
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 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.
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.
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.
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.
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.
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.
● 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.
3.1 Overviews
Item Designation
1 Pressure gauge for hydraulic fluid filter wear
3 Control cabinet
(Control cabinet P. 3 — 26)
Core pump operating panel
(Core pump operating panel P. 3 — 27)
5 Cable remote control
(Cable remote control P. 3 — 47)
6 Hydraulic fluid radiator
Item Designation
1 Coolant filler opening
(with vent valve)
3 Fuse box
4 Battery
Item Designation
1 Fluid drain cock
Item Designation
5 Fuel filler opening
3.2.1 Overview
Item Designation
1 Grille
2 Spray guard
3 Protective grille
(on the hydraulic fluid radiator)
5 Protective grille
(on the motor oil radiator)
Item Designation
7 Protective grille
(on the water box)
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.
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.
Item Designation
Left Spare parts sheet
1 2 3 4 5
BP15_013_1412DE 2
Item Designation
1 Asterisk “*” – item cannot be ordered
Item Designation
4 Hourglass – SRP service life
3.2.4 Plates
You will find the locations of the plates on the machine circuit dia‐
grams, which indicate which plate should be affixed where.
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.
3.2.5.1 Function
Area Action
Core ● The agitator stops
pump ● The transfer tube stops
● The delivery pistons stop
● 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
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.
Item Designation
1 Press: Locks EMERGENCY STOP button
3.2.6.1 Structure
The agitator safety cutout is located on the hopper. The installation lo‐
cation on the hopper varies.
Item Designation
1 Reading head (on the hopper – example illustration)
3.2.6.2 Function
As soon as you open the grille, the radio link between the transpond‐
er and the reading head is broken.
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.
You can deactivate the agitator safety cutout on the core pump oper‐
ating panel.
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.
3.2.7 Grille
Monthly
WARNING
Moving parts in the hopper
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.
Designation Value
Output per year 20,000 [m3]/year
Designation Value
Maximum operating altitude 2500 m
Designation Value
Stationary concrete pump with diesel -8 – +45 °C
engine*
Machine data
Item Designation
1 Manufacturer's address
2 Machine model
4 Machine number
5 Chassis number
6
marking
7 Year of manufacture
8 not present
Item Designation
Operating data
Item Designation
9 Maximum fluid pressure in the hydraulic system
12 not present
13 Gross weight
14 not present
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.
Close to the machine's rating plate, you will find the plate that is
shown below, which specifies the guaranteed sound power level of
the machine.
Its electromagnetic compatibility has been tested and meets the fol‐
lowing requirements:
● DIN EN ISO 13766-2:2018
P200384
The operator can object to the transfer of operating data at any time.
connectedservices@putzmeister.com
The After Sales Service personnel and your dealer can identify prob‐
lems more quickly using the “Remote Service” web app.
The operating company can monitor data regarding the machine’s op‐
erating state as well as its location with the “Machine Cockpit” web
app.
3.8.1 Function
The engine and the exhaust after treatment system are coordinated
with each other.
Term Description
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 — 23)
3.8.2 Regeneration
Designation Value
Duration Approx. 40 min
The diesel particle filter fills up with the filtered out diesel particles
during operation. Diesel particles are burned during normal operation.
The exhaust after treatment system will be damaged if you fail to start
regeneration when it is required despite a higher escalation level.
The display on the control cabinet will show messages when regener‐
ation is advisable or required.
(Messages P. 3 — 43)
WARNING
Risk of burning
▶ Stay clear of the exhaust after treatment system – particularly
during and after regeneration.
You can interrupt the regeneration process and start it again later.
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
Operating elements
Item Designation
1 Display
(Display P. 3 — 29)
2 Core pump operating panel
(Core pump operating panel P. 3 — 27)
3 Keyswitch with the following switch positions:
Machine off
Control system on
Engine on
Connections
Item Designation
4 Diagnostics socket
6 Power supply
7 Motor
8 Core pump
9 Remote control
(radio receiver or cable remote control)
11 Vibrator
Button Function
● Deactivating the EMERGENCY STOP
● Horn
(sounds for as long as the button is pressed)
Deactivating the agitator safety cutout
Table 5: Column 1
Button Function
Forward pumping On/Off
Table 6: Column 2
Button Function
Increasing output
Reducing output
Vibrator On/Off
Table 7: Column 3
Button Function
Increase motor speed
Table 8: Column 4
Button Function
Agitator On/Off – for forward pumping
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.
3.13 Software
The software is operated with the display’s operating elements:
(Display P. 3 — 29)
The software starts with the main menu.
Navigation bar
(only in main menu)
Menu content
Function bar
Symbol Menu
User settings
Core pump
Motor
Machine information
Item Designation
1 Hydraulic fluid temperature
3 Current output
(in m3/h and in %)
Forward pumping
Reverse pumping
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.
Fill-level sensor on
Hopper filled
Fill-level sensor on
Hopper empty
Core pump stopped automatically
Switchover behaviour of the transfer tube
Automatic configuration
Hard switchover
Soft switchover
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
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
(Messages P. 3 — 43)
The bar chart shows the core pump’s general operating parameters.
Symbol Description
Hydraulic fluid temperature
Current output in %
Colour Description
Inactive
Active
Fault
Colour Description
Inactive
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
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.
Fill-level sensor on
Hopper filled
Fill-level sensor on
Hopper empty
Core pump stopped automatically
Switchover behaviour of the transfer tube
Automatic configuration
Hard switchover
Soft switchover
Symbol Description
Speed
Power supply
Fuel indicator
Double display
● Fill level (ratio)
● Consumption ( l/h)
Symbol Description
Remaining runtime of the regeneration
Regeneration active
Symbol Description
Start regeneration
Stop regeneration
Observe the notes on exhaust after treatment!
Table 14: Function bar in the “Motor” menu
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 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.
Colour Description
Inactive/not present
Active
Fault
Row Description
pmSCP_C Control system software version
pmSCP_D Display software version
Table 16: Software versions
Symbol Description
Reset transfer tube position values
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
Stroke duration 1
in seconds
Stroke duration 2
in seconds
Symbol Description
Reset daily meter (trip)
(press and hold for several seconds)
3.13.7 Messages
3.13.7.2 Motor
Motor messages are triggered by a fault signal from the motor. The
fault signal is sent from the motor to the control cabinet.
DPF full: Level 1 Start regeneration during the next cleaning opera‐
tion
(Exhaust after treatment P. 3 — 22)
● DPF full: Level 2 Start regeneration immediately
(Exhaust after treatment P. 3 — 22)
● DPF full: Level 3 Have regeneration started by the motor manufac‐
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 21: Diesel particle filter
Hydraulic fluid temperature too Check hydraulic fluid radiator and clean if neces‐
high sary
3.14.1 Structure
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
Increasing output
Reducing output
3.15.1 Structure
Item Designation
1 Drive cylinder
2 Water box
3 Delivery cylinder
4 Delivery piston
5 Transfer tube
7 Agitator
8 Hopper
3.15.2 Function
3.15.3 Reversal
3.15.4.1 Structure
Item Designation
1 Lid
2 Seal
3 Grille
4 Water outlet
5 Water box
3.15.4.2 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.
Prerequisites:
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
3.15.5 Agitator
3.15.5.1 Structure
Item Designation
1 Mixing paddle
2 Mixer shaft
3 Agitator drive
3.15.5.2 Function
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.
The agitator and water pump are mutually locked. Only one of the
functions can be active at any one time.
Prerequisites:
✓ You have familiarised yourself with the agitator functions.
(Function P. 3 — 54)
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.
3.15.6 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.
Item Designation
1 Grille
2 Vibrator
3 Supply line
4 Plug
You can switch the vibrator on and off at the following locations:
● Core pump operating panel
(Core pump operating panel P. 3 — 27)
There are two magnetic switches on each drive cylinder of the core
pump, one at the rod side and one at the piston side.
3.15.7.1 Structure
2
1
4
3
1
Item Designation
1 Schematic illustration of the magnetic switch installation locations and
numbering
3 Magnetic switch distributor casing with indicator lights: One yellow LED
per connection, one green LED for the housing (in service light)
3.15.7.2 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.
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
Item Designation
1 Green and yellow LEDs
2 Connector
3 Magnetic switch
The yellow LED indicates the status of the magnetic switch, the green
LED indicates the status of the connector and the lead.
3.16.1 Structure
Item Designation
1a Lubricant reservoir
1b Air bleeder
1c Lubricant pump
2 Grease gun
3 Lubricant distributor
3.16.2 Function
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.
3.17.1 Structure
Item Designation
1 Water supply
2 Water outlet
(connection for cleaning gun)
3 Drain cock
3.17.2 Function
NOTICE
Damage caused by frost
Any residual water in the water pump may freeze and damage it.
▶ Drain any residual water from the water pump if there is a risk of
freezing ‐ even during site use.
Designation Value
Generated water pressure 20 bar
WARNING
Risk of death from pumping incorrect functional fluids
1. Do not pump foodstuffs.
2. Only pump water.
3. Use only commercially available cleaning agents.
WARNING
Risk of injury
1. Hold the cleaning gun and lance firmly in your hand or ensure
that the cleaning gun is located in a secure holder.
2. Never point the gun at people, animals or electrical components
of the machine (e.g. control cabinet, electric motors).
3. Prevent the water jet from being deflected towards people, ani‐
mals or electrical components.
4. Wear protective goggles and protective clothing.
CAUTION
Rebound from cleaning gun
1. Ensure that the cleaning gun is located in a secure holder be‐
fore you start up the high-pressure water pump.
2. Never lock the lever on the cleaning gun.
NOTICE
Material damage
The water jet of the high-pressure water pump can damage surfa‐
ces.
▶ Maintain a minimum distance of 30 cm between the nozzle and
the surface you wish to clean.
You can switch on the water pump at the following operating posi‐
tions:
● Lever for switching over between the water pump and the agitator
Prerequisites:
✓ Water supply is connected
(Connecting the water supply P. 4 — 16)
✓ Water temperature: 5–60 °C
✓ Water supply shut-off valve is open
✓ Water pump drain cock is connected
✓ Cleaning gun is connected to the water outlet of the water pump
✓ Machine is switched on
The agitator and water pump are mutually locked. Only one of the
functions can be active at any one time.
The agitator and water pump are mutually locked. Only one of the
functions can be active at any one time.
Prerequisites:
✓ Flushing water pump is switched off
l (Switching off the water pump P. 3 — 66)
CAUTION
Risk of injury
▶ Do not undo the threaded unions and quick-release couplers
from the pressure hose and cleaning gun until the water system
of the water pump is depressurised.
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 — 29)
✓ You have checked the gross weight of the machine.
(Machine rating plate P. 3 — 19)
✓ The machine accessories are secured.
1. Support the machine with the support wheel or the support feet.
Item Designation
1 Attachment bracket
4.1.2 Driving
Designation Value
Maximum permissible speed 8 km/h
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.
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.
45°
▶ Maintain the minimum clearance “a” even for a low-depth pit and
ground with a high loadbearing capacity.
A 2 T A 1 T
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 20: Do not support the machine on unsuitable supporting ground surfaces
Item Designation
1 Rear support feet
2 Crank
3 Rotating support
5 Towing ring
Item Designation
1 Lever for support foot control
(for each side)
Symbol Meaning
Lower support foot
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.
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.
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.
If the forward support foot is folded up, you need to fold it down.
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.
5. Secure the stop pin with the spring pin.
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.
(Cleaning P. 5 — 29)
Item Designation
1 Connection for water feed
Designation Value
Required volumetric flow rate 80 l/min
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.
The deployment of a damaged machine for site use may lead to long-
term consequential damage.
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.
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.
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 switched off.
✓ The machine is horizontal.
✓ The supports are retracted.
✓ The water box is filled.
MAX
MIN
MAX
MIN
● 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.
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)
Prerequisites:
✓ The drive motor is switched on.
✓ The core pump is switched off.
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.
You can deactivate the agitator safety cutout on the core pump oper‐
ating panel.
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)
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.
Item Designation
1 Press: Locks EMERGENCY STOP button
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.
Only use the pump if you cannot detect any visible damage to the
pump or adjacent components.
If one of the LEDs does not light up, the magnetic switch is defec‐
tive.
▶ When the delivery pistons are moving slowly, press and hold the
CHANGE-OVER BUTTON on the remote control.
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.
Clogged hydraulic fluid filters reduce the hydraulic fluid flow consider‐
ably with the result that damage may occur in the hydraulic system.
Prerequisites:
✓ The water box is filled with water.
✓ The machine is switched on.
✓ The temperature of the hydraulic fluid is at least 50 °C.
Prerequisites:
✓ The water box is filled with water.
✓ The machine is switched on.
✓ The temperature of the hydraulic fluid is at least 50 °C.
▶ With your arms stretched out to the side, move both arms quickly
up and down.
▶ With one arm crooked, place your elbow into the palm of your
other hand.
▶ Hold both arms above your head with your hands clasped togeth‐
er.
⇒ 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.
5.6 Pumping
Prerequisites:
✓ You have started up the machine.
(Starting up P. 5 — 3)
✓ You have supported the machine.
(Supporting the machine P. 4 — 5)
✓ You have checked the functions.
(Checking the functions P. 5 — 9)
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.
Entrapped air can become compressed air at the end of the delivery
line, which can be released suddenly, ejecting the concrete violently.
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.
The agitator and water pump are mutually locked. Only one of the
functions can be active at any one time.
Prerequisites:
✓ You have familiarised yourself with the agitator functions.
(Function P. 3 — 54)
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.
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”.
Prerequisites:
✓ The machine is supported.
(Supporting the machine P. 4 — 5)
✓ You have filled the water box.
You must wet the entire delivery line at the start of pumping opera‐
tions.
1. Insert two sponge balls into the delivery line through the wash-out
port.
2. Make sure that nobody is in the danger zone by the end hose.
⇒ (End hose P. 2 — 10)
3. Switch the agitator on.
4. Fill the hopper with grout.
Prerequisites:
✓ You have started to pump concrete.
The machine will become worn during pumping. Lubricants and func‐
tional fluids are consumed.
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.
5.6.9.1 Blockage
Item Designation
1 Wedged aggregate
2 Cement paste
3 Boundary layer
5.6.9.3 Overheating
90 °C
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.
Additional cooling
5.7 Cleaning
WARNING
Moving parts in the hopper
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.
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.
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
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.
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.
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.
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.
Item Designation
1 Coupling
4 Catch bracket
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.
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
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.
Item Designation
1 Pressure gauge
2 Guard bracket
6 Dump cock
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:
✓ The machine is switched off.
Item Designation
1 Adhesive tape marking
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.
1. Make sure that the sheet is suitable for the concrete residue load.
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.
WARNING
Risk of death from pumping incorrect functional fluids
1. Do not pump foodstuffs.
2. Only pump water.
3. Use only commercially available cleaning agents.
WARNING
Risk of injury
1. Hold the cleaning gun and lance firmly in your hand or ensure
that the cleaning gun is located in a secure holder.
2. Never point the gun at people, animals or electrical components
of the machine (e.g. control cabinet, electric motors).
3. Prevent the water jet from being deflected towards people, ani‐
mals or electrical components.
4. Wear protective goggles and protective clothing.
CAUTION
Rebound from cleaning gun
1. Ensure that the cleaning gun is located in a secure holder be‐
fore you start up the high-pressure water pump.
2. Never lock the lever on the cleaning gun.
NOTICE
Material damage
The water jet of the high-pressure water pump can damage surfa‐
ces.
▶ Maintain a minimum distance of 30 cm between the nozzle and
the surface you wish to clean.
You can switch on the water pump at the following operating posi‐
tions:
● Lever for switching over between the water pump and the agitator
Prerequisites:
✓ Water supply is connected
(Connecting the water supply P. 4 — 16)
✓ Water temperature: 5–60 °C
✓ Water supply shut-off valve is open
✓ Water pump drain cock is connected
✓ Cleaning gun is connected to the water outlet of the water pump
✓ Machine is switched on
The agitator and water pump are mutually locked. Only one of the
functions can be active at any one time.
Symbols
Item Designation
1 Sponge pig
2 Sponge cube
3 Sponge ball
4 Wash-out pig
WARNING
Risk of injury
Concrete can spray out of the hopper during reverse pumping.
1. Wear protective goggles.
2. Wear respiratory protection.
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.
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.
3. Switch off the core pump.
4. Remove the wash-out port lid.
5. Remove the wash-out sponge.
6. Fit the wash-out port lid.
Item Designation
1 Gate valve
3 Container
Prerequisites:
✓ There is no end hose fitted at the end of the delivery line.
Pumping water
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.
Prerequisites:
✓ You have connected a wash-out tower to the delivery line or instal‐
led a delivery line to a container.
Item Designation
1 Gate valve
2 Catch basket
Item Designation
1 Wash-out adaptor
3 Concrete
Item Designation
1 “Water” connection
2 Water
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.
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.
Prerequisites:
✓ You have familiarised yourself with the warning notices for clean‐
ing:
(Cleaning P. 5 — 29)
✓ You have cleaned the delivery line.
(Clean the delivery line P. 5 — 39)
✓ If your machine has a level control:
The level control is switched off.
▶ When restarting, switch the concrete pump off first, and then back
on again.
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
Prerequisites:
✓ You have connected a water supply.
(Connecting the water supply P. 4 — 16)
Prerequisites:
✓ You have familiarised yourself with the warning notices for clean‐
ing:
(Cleaning P. 5 — 29)
✓ You have marked a water hose.
(Marking the water hose P. 5 — 35)
Figure 56: Spray out the transfer tube valve and delivery cylinder in cases where the
concrete pump is running backwards slowly
Figure 57: Feed the water hose into the hydraulic diversion valve up to the mark
Item Designation
1 Transfer tube
2 Thrust ring
3 Wear ring
▶ 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.
5.7.6.6 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.
6
5
Item Designation
1 S transfer tube
5 Lubrication points
6 Hinged elbow
2 3 2 4
Item Designation
1 Lettering “0” or milling
4 Hinged elbow
5 Wedge
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.
Prerequisites:
✓ The remote control is switched off.
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.
The agitator and water pump are mutually locked. Only one of the
functions can be active at any one time.
▶ Document the date that the machine is placed into storage and
the value preservation measures that are carried out.
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.
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 — 63)
5.8.6 General measures to preserve the value of the concrete pump as‐
sembly
Item Designation
3701 Delivery rate regulation using potentiometer
3706 Pumping On
Item Designation
3717 Changeover
6002 Radiator
6003 Radiator 1
6004 Radiator 2
6011 Air
Item Designation
6014 Filter element
7001 Spotlights
7002 Lighting
8007 Start
8009 Menu
9003 Teleservice
Item Designation
10005 Acknowledge cooling water excess temperature
10009 Speed
10015 Silent
10020 Starter
12001 Horn
12003 Acknowledge
12004 Battery
12008 Stop
12010 Vibrator On
Item Designation
12011 Vibrator Off
12012 Vibrator
12013 Potentiometer
12014 Off - On
12015 On
12016 Off
12019 Compressor
12026 Automatic/manual
12031 Cleaning
12039 Buzzer
12040 Container
12042 Lock
12044 Circuit 1
Item Designation
12045 Circuit 2
12050 Generator
12056 Water
A
ADR (Speed of rotation regulation
P. B — 17)
(Grille P. B — 14)
B
Blockage Blockage in the delivery line:
C
Changeover Reversal of the delivery pistons’
direction in the middle of the
stroke movement:
D
dB Decibels: Unit of measurement for
the (Sound power level
P. B — 16)
E
EDC (Electronic Diesel Control
P. B — 12)
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.
G
Grille The grille is the cover grille for 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:
O
Operating equipment Battery, filters
P
PEDOC Putzmeister Electronic Documen‐
tation
Piston side
R
Reversal The concrete is sucked back from
the delivery line into the hopper.
Rod side
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
the compressor, rather than the
pump, at the remote control if you
switch the switch to the ““compres‐
sor”” position.
T
Teach-in Specialist word for storing in mem‐
ory
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.
C Cleaning preparations P. 5 — 31
Centralised lubrication system P. 3 — 61 Cleaning the gap between the transfer tube bearing and
the transfer tube P. 5 — 57
Changes to the machine P. 2 — 15
Cleaning the hopper P. 5 — 54
Check function P. 3 — 8
Cleaning the remote control P. 5 — 60
Checking functional fluids P. 5 — 6
Cleaning with compressed air P. 2 — 44, 5 — 47
Checking that the machine is ready for operation
P. 2 — 21 Cleaning with pressurised water P. 5 — 45
Checking the agitator safety cutout P. 3 — 14, 5 — 11 Clean the delivery line P. 5 — 39
Entire machine P. 3 — 44
D
Exclusion of liability P. 2 — 16
Danger due to high voltage P. 2 — 22
Exhaust after treatment P. 3 — 22
Dangers during pumping P. 5 — 20
Extending the placing boom and end hose P. 2 — 13
Danger zone P. 2 — 9
Extending the reach P. 2 — 13
Deactivating the agitator safety cutout P. 3 — 13, 5 — 9
Extend supports P. 4 — 11
Deactivating the EMERGENCY STOP P. 3 — 9, 5 — 8
Definition of terms P. 2 — 3 F
Delivery line systems P. 2 — 4, 2 — 10, 2 — 37 Filling the lubricant reservoir P. 3 — 62
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 — 64
Improper use P. 2 — 12
General measures to preserve the value of the electrical
system assembly P. 5 — 62 Indicator lights P. 3 — 58
General measures to preserve the value of the engine “Inputs and outputs” menu P. 3 — 41
assembly P. 5 — 64 Inserting the wash-out sponge P. 5 — 46
General measures to preserve the value of the hopper Insert the wash-out sponge P. 5 — 42
assembly P. 5 — 64
Inspection intervals for retesting P. 2 — 11
General measures to preserve the value of the water
assembly P. 5 — 64
L
General measures to preserve value P. 5 — 62
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
Maintaining the centralised lubrication system Operating Instructions, operating procedures and other
P. 3 — 62 regulations P. 2 — 17
Mobile machines P. 2 — 6, 2 — 27 P
“Motor” menu P. 3 — 38 Personal protective equipment P. 2 — 19
Motor P. 3 — 44 Personnel P. 2 — 16
Motor fault codes P. 3 — 40 Place of work P. 2 — 8, 2 — 40
Motor overload P. 5 — 26 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
Plates P. 3 — 8
O Positions of the EMERGENCY STOP buttons P. 3 — 9
Observe the notes on cleaning P. 5 — 31
Post-cleaning procedure P. 2 — 46
Opening delivery lines P. 2 — 39
Pre-fitting the catch basket P. 5 — 32
Operating altitude P. 3 — 18
Preparing cement bags P. 5 — 35
Operating data P. 3 — 20
Procedure in storms P. 2 — 36
R Software P. 3 — 30
Rendering the machine ready for operation P. 2 — 21 Starting the pumping process P. 5 — 24
Reverse pumping the concrete P. 5 — 42 Structure P. 3 — 12, 3 — 47, 3 — 49, 3 — 51, 3 — 54,
3 — 57, 3 — 61, 3 — 64
S Subject expert P. 2 — 5
Safe clearance from pits P. 4 — 8 Sucking in air P. 5 — 20
Safely using the remote control P. 3 — 48 Suction cleaning P. 5 — 41
Safety P. 2 — 40 Suitable delivery lines P. 2 — 37
Safety components P. 3 — 6 Supporting ground P. 2 — 28, 4 — 9
Safety equipment P. 3 — 5 Supporting the machine P. 4 — 5
Symbols P. 5 — 39
T
T delivery pipe with wash-out port P. 5 — 32
Test run P. 5 — 3
Towing P. 2 — 32
Transporting P. 4 — 3
Transporting goods P. 2 — 12
Truck mixer P. 2 — 4, 2 — 42
U
Unfold placing boom P. 2 — 33
V
Vibrator P. 3 — 56
2021-08-09
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
Table of contents
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
Index ........................................................................................ C —1
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
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.
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.
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)
Fault rectification – Instructions to be carried out
in accordance with fault messages.
Icon/symbol/ Meaning
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.
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
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
Indicates a dangerous situation in which an accident resulting in se‐
rious or fatal injuries may occur.
▶ After identifying the risk, instructions are set out which are inten‐
ded to avoid or remedy the risk.
CAUTION
There is a risk of injury to the entire body, however there is no risk
of serious or fatal injuries.
▶ After identifying the risk, instructions are set out which are inten‐
ded to avoid or remedy the risk.
NOTICE
Risk of damage to the machine. There is no risk of injury.
▶ After identifying the risk, instructions are set out which are inten‐
ded to avoid or remedy the risk.
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.
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.
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.
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‐
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.
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.
Support the placing boom arms before starting work on the valves,
cylinders or hydraulic lines on the boom.
The delivery line was installed without tension with the placing boom
in the driving position and can only be replaced without difficulty in
this condition. Stresses may be generated on folding if the delivery
line is replaced when the placing boom is unfolded.
Do not remove the 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.
2.6 Software
If a machine is equipped with software, the software may only be
used as is provided for in the manufacturer’s Operating Instructions.
Keep all warning signs and information plates on the machine com‐
plete and in a perfectly legible condition.
2.8.1 General
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.
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.
2.9.1 General
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.
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.
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.
Take care when handling hot functional fluids and consumables (risk
of burning or scalding).
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.
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 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.
Item Designation
1 Hydraulics control block of the core pump
Item Designation
1 Switch over the transfer tube
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)
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.
8. Fit the casing in front of the pump control system again following
emergency operation.
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.
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.
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
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.
WARNING
Risk of injury from the machine starting unexpectedly
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.
3. Wear your personal protective equipment.
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.
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.
2. Wear your personal protective equipment.
Tightening tool:
● Manual torque wrench
in accordance withDIN EN ISO 6789
● Preferably version with display
● Suitable for specified torque
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.
Always replace bolts with bolts of the same size and grade.
▶ The maximum tightening torques for set screws and nuts can be
found in the spare parts list.
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
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.
6 L 30
8 L 35
10 L 40
12 L 55
15 L 80
18 L 110
22 L 140
28 L 210
35 L 300
42 L 400
RAD = pipe external diameter
MA = tightening torque
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
RAD = pipe external diameter
MA = tightening torque
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.
NOTICE
Machine damage caused by lubricants with dangerous additives
▶ Never use hydraulic fluids or lubricants with additives such as
molybdenum.
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.
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.
68 mm2/s ISO VG
● Use at 0 °C to
+95 °C
HLP 68
● Material number:
279845.009
Changeover guidelines - VDMA 24569 -
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.
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).
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.
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.
4.5.4.2 Greases
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.
4.6.1.1 General
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.
4.6.1.3 Hydraulics
1. Check that the display on the vacuum meter of the vacuum filter
is still in the green range.
Fluid analysis
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.
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
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.
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.
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.
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.
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.
WARNING
Risk of injury
Mechanically pre-stressed hydraulic hose lines can become detach‐
ed and cause injury due to impact.
▶ Exercise the necessary caution.
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.
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
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.
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.
Item Designation
1 Filter element
2 Filter housing
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
The agitator drive housing does not turn with the mixer shaft.
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.
WARNING
Risk of death
1. Pressure in the hydraulic system may cause sudden machine
movements.
2. Before commencing work on the plant, check the pressure
gauge to ensure that the hydraulic fluid pressure in the plant
has been completely dumped.
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.
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.
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.
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.
To replace the delivery pistons, you may work with the remote control
on the flatbed.
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.
Item Designation
1 Piston rod flange
2 Fastening bolts
3 Retaining rings
Item Designation
4 Delivery piston
5 Spacer flange
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).
Item Designation
1 Jacking bolts
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.
19. Start the machine up.
20. Slowly extend the drive piston.
⇒ The new delivery piston is pushed into the delivery cylinder.
⇒ The jacking bolts remain freely accessible.
21. Shut the machine down.
22. Unscrew the jacking bolts.
23. Put on the protective caps.
24. Start the machine up.
25. Retract the drive piston.
⇒ The spacer flange fits between the delivery piston and the
drive piston.
26. Shut the machine down.
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 — 41)
Prerequisites:
✓ You have replaced both delivery pistons.
✓ The stroke correction lines are closed.
You can carry out the following steps at the same time for both ball
valves.
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.
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).
Measuring
The resolver measures the position of the transfer tube and con‐
trols the graphical display of the Ergonic software.
Item Designation
1 Resolver
2 Connecting cable
4 Switch cylinders
5 Switch lever
▶ Fit the resolver (1) in such a way that the shaft marking (3) on the
bearing shaft points in the direction of the connecting cable (2).
WARNING
Risk of death
The hydraulic system is pressurized. Sudden machine movements
may occur during operation.
1. Shut the machine down.
2. Secure the machine against unauthorized or accidental starting
up.
Prerequisites:
✓ The machine is cleaned.
WARNING
Risk of death
1. Pressure in the hydraulic system may cause sudden machine
movements.
2. Before commencing work on the plant, check the pressure
gauge to ensure that the hydraulic fluid pressure in the plant
has been completely dumped.
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
The mounting position for the gasket set in the transfer tube bear‐
ing can be found in the corresponding spare parts sheet.
Item Designation
1 Pressure connection
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.
1 2 3 4 5 6 7 8 9 10
13 12 11
Item Designation
1 Pulling bore for ball cup
2 Ball cup
3 Hydraulic port
4 Plunger cylinder
5 Retaining plate
7 Switch lever
8 Washer
9 Switching shaft
10 Hexagon nut
WARNING
Risk of death
1. Pressure in the hydraulic system may cause sudden machine
movements.
2. Before commencing work on the plant, check the pressure
gauge to ensure that the hydraulic fluid pressure in the plant
has been completely dumped.
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.
The switching shaft of the transfer tube is mounted in the front wall of
the hopper in the switching shaft bearing.
The resolver for detecting the position of the transfer tube is located
in front of the switching shaft.
Prerequisites:
✓ You have shut down the machine.
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.
Item Designation
1 Switch lever
2 Pulling bolt
16. Remove the hexagon nut and the washer from the switching
shaft.
17. Remove the O-ring from the switching shaft (if present).
18. Pull the switch lever from the switching shaft.
Item Designation
1 Fastening bolt
2 Pulling bore
two diagonally opposite each other
For the mounting position of the grooved ring in the flanged bear‐
ing, please refer to the accompanying spare parts sheet.
Replacing the switching shaft bearing wear sleeve and collared wash‐
er
Item Designation
1 Switching shaft bearing wear sleeve
3 Collared washer
4 Bore
5 Tab
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.
Item Designation
1 Pressure connection
2 Pressure flange
3 Hexagon nut
4 Hopper
Item Designation
1 Rear wall of the hopper
3 no clearance = incorrect
Item Designation
1 Bore: Rear 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.
⇒ The switching shaft and the bore on the front wall of the hop‐
per are concentric.
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.
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.
Item Designation
1 Pressure connection
2 Pressure flange
3 Hexagon nut
4 Hopper
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.
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.
WARNING
Risk of death
The hydraulic system is pressurized. Sudden machine movements
may occur during operation.
1. Shut the machine down.
2. Secure the machine against unauthorized or accidental starting
up.
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
1. Pressure in the hydraulic system may cause sudden machine
movements.
2. Before commencing work on the plant, check the pressure
gauge to ensure that the hydraulic fluid pressure in the plant
has been completely dumped.
Item Designation
1 S transfer tube with bolted switching shaft
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 — 42) and ( Measuring the wall thickness of a two-layer pipe
P. 4 — 106)
7. Unbolt the scratch bar from the bottom of the S transfer tube.
8. Push the S transfer tube forwards until the transfer tube outlet is
uncovered.
9. 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)
10. Fit the new S transfer tube. To do this, proceed in the reverse or‐
der to removal.
11. Fit a new thrust ring and a new wear ring. (Replacing the thrust
ring and wear ring P. 4 — 90)
12. Fit the switching shaft bearing (flanged bearing). (Replacing the
switching shaft bearing P. 4 — 51)
13. Fit the transfer tube bearing. (Replacing the transfer tube bearing
P. 4 — 46)
14. Adjust the S transfer tube so that it switches correctly. (Adjusting
the S transfer tube P. 4 — 93)
WARNING
Risk of death
The hydraulic system is pressurized. Sudden machine movements
may occur during operation.
1. Shut the machine down.
2. Secure the machine against unauthorized or accidental starting
up.
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
1. Pressure in the hydraulic system may cause sudden machine
movements.
2. Before commencing work on the plant, check the pressure
gauge to ensure that the hydraulic fluid pressure in the plant
has been completely dumped.
1 2 3 4 1
5 5 5
Item Designation
1 Plunger cylinder
2 Switch lever
3 Switching shaft
4 Hexagon nut
If there is not enough space available for assembly, you can pull
the pressure connection towards the back.
5. Push the transfer tube away from the spectacle wear plate.
6. Unscrew the eight fastening bolts for the spectacle wear plate.
7. Remove the spectacle wear plate from the hopper.
Item Designation
1 Transition liner
2 Intermediate ring
3 Screw plug
4 Lubrication nipple
5 Grease gun
Item Designation
1 Intermediate ring
2 O-rings
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.
1 1
Item Designation
1 Fastening bolts on the left and right
4 Intermediate ring
5 Oring
6 Hopper wall
7 Clearance
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.
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.
WARNING
Risk of death
The hydraulic system is pressurized. Sudden machine movements
may occur during operation.
1. Shut the machine down.
2. Secure the machine against unauthorized or accidental starting
up.
WARNING
Risk of death
1. Pressure in the hydraulic system may cause sudden machine
movements.
2. Before commencing work on the plant, check the pressure
gauge to ensure that the hydraulic fluid pressure in the plant
has been completely dumped.
CAUTION
Risk of injury
Risk of burning when heating and pushing on the new wear sleeve.
▶ Wear suitable protective equipment.
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.
Item Designation
1 Welds
3 Wear sleeve
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).
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).
Item Designation
1 Wear sleeve
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.
5. Fit the transfer tube bearing. (Replacing the transfer tube bearing
P. 4 — 46).
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 — 51).
WARNING
Risk of death
The hydraulic system is pressurized. Sudden machine movements
may occur during operation.
1. Shut the machine down.
2. Secure the machine against unauthorized or accidental starting
up.
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
1. Pressure in the hydraulic system may cause sudden machine
movements.
2. Before commencing work on the plant, check the pressure
gauge to ensure that the hydraulic fluid pressure in the plant
has been completely dumped.
Item Designation
1 Thrust ring
2 Wear ring
6. Remove the old wear ring (2) and the old thrust ring (1).
4. Fit the transfer tube bearing. (Replacing the transfer tube bearing
P. 4 — 46)
5. Fit the resolver using the hexagon head bolt on the switching
shaft. (Fitting the switching shaft resolver P. 4 — 45)
6. Adjust the S transfer tube. (Adjusting the S transfer tube
P. 4 — 93)
WARNING
Risk of death
The hydraulic system is pressurized. Sudden machine movements
may occur during operation.
1. Shut the machine down.
2. Secure the machine against unauthorized or accidental starting
up.
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
1. Pressure in the hydraulic system may cause sudden machine
movements.
2. Before commencing work on the plant, check the pressure
gauge to ensure that the hydraulic fluid pressure in the plant
has been completely dumped.
Item Designation
1 Spectacle wear plate
2 Wear ring
3 S transfer tube
4 Thrust ring
5 Gap
6 Hexagon nut
7 Retaining plate
Ensure that the thrust ring (4) does not become damaged during
injection.
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.
4. Check all sides to ensure that the wear ring (2) is touching the
spectacle wear plate (1).
5. 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.
6. Ensure that for re-attaching the retaining plate (7) one surface of
the hexagon nut (6) is horizontal at the top.
7. Fit the retaining plate (7).
8. Carry out further assembly in the reverse sequence to disassem‐
bly. (Fitting the switching shaft resolver P. 4 — 45)
9. Check that all covers and other safety equipment have been refit‐
ted and are fully functional.
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.
Item Designation
1 Marking on the spectacle wear plate
Item Designation
1 Swing angle too great
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.
Item Designation
1 Packing washer too thin
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.
Item Designation
1 Plunger cylinder (switch cylinder)
2 Locking plate
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.
Item Designation
1 Ball cup
2 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.
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.
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.
Elbows
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.
Measuring
Item Designation
1 High pressure
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.
Table 3: Extract from Esser Service Manual - EM 070190, see Technical Appendix
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
Assembling the transfer tube bearing P. 4 — 51, 4 — 66 Emergency operation of the core pump P. 3 — 4
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 — 60
Carrying out visual checks P. 4 — 19
Fitting the switching shaft resolver P. 4 — 45
Changing the hydraulic fluid in the hydraulic fluid reser‐
Fitting the thrust ring and wear ring P. 4 — 92
voir P. 4 — 21
Fitting the wear sleeve P. 4 — 89
Checking hydraulic hose lines for leaks P. 4 — 26
Fitting threaded unions P. 4 — 9
Checking the concentricity of the mixer shaft P. 4 — 32
Fitting WALFORMplus threaded unions P. 4 — 12
Checking the threaded unions P. 4 — 28
Fluid analysis P. 4 — 21
Closing the stroke correction lines P. 4 — 36
Foreword P. 1 — 3
Core pump P. 4 — 32
Functional fluids P. 2 — 11, 4 — 13
D
Delivery line P. 4 — 102 G
General P. 2 — 7, 2 — 8, 4 — 19
Dismantling the S transfer tube P. 4 — 71
General tightening torques P. 4 — 8
Dismantling the transfer tube bearing P. 4 — 49
Greases P. 4 — 18
Disposal of the machine P. 2 — 12
Guide to the Service Instructions P. 1 — 1
Draining the hydraulic fluid P. 4 — 23
E H
Hydraulic fluid reservoir capacity P. 4 — 15
Elbows P. 4 — 103
Hydraulic fluids P. 4 — 13
Electrical components P. 2 — 8
Hydraulics P. 4 — 20 O
Hydraulic system P. 4 — 20 Opening the stroke correction lines P. 4 — 41
Hydraulic systems P. 2 — 8
P
I Personal protective equipment 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
Replacing the switching shaft bearing gasket set S transfer tube variants P. 4 — 71
P. 4 — 58
Replacing the switching shaft bearing wear sleeve and T
collared washer P. 4 — 60 Tightening torques P. 4 — 11
Replacing the thrust ring and wear ring P. 4 — 90 Transmission fluid P. 4 — 18
Replacing the transfer tube bearing P. 4 — 46
Replacing the transfer tube wear sleeve P. 4 — 84 Working on the placing boom P. 2 — 5
Residual risks P. 4 — 6
S
Safety regulations P. 2 — 1
Safetyrelevant components P. 2 — 6