ManualArchive 2106T2391 Operating Instructions

Operating Instructions
TK70
2106T2391
Vehicle Series (VS)
TK Series Trailer-Mounted
A820090D
Table of Contents
1 Guide to the Operating Instructions . . . 1–1

1.1 Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2
1.2 Icons and Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
2 Safety Regulations . . . . . . . . . . . . . . . . . . 2–1

2.1 Personnel Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2
2.2 Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2
3 General Technical Description . . . . . . . . 3–1

3.1 Principles of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2
3.2 Flat Pack Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3
3.3 Thom - Katt, Katt Kreter and King Katt Series Trailer-Mounted
Overview Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4
3.4 TKS Skid-Mounted Overview Diagram . . . . . . . . . . . . . . . . . . . . . 3–5
3.5 Vehicle Series (VS) Overview Diagram . . . . . . . . . . . . . . . . . . . . 3–6
3.6 Vehicle Series Power Take-Off (VS PTO)

Overview Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–7
3.7 Machine Rating Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–8
3.8 Symbols for the Control System . . . . . . . . . . . . . . . . . . . . . . . . . . 3–9

3.8.1 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–9
3.8.2 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–9
3.8.3 Concrete Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–10
3.9 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–11
3.10 Electric Control Cabinet Thom - Katt, Katt - Kreter,

VS (Vehicle Series) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–12
3.10.1 Deutz Engine Display and Control Module (if equipped) . . . . . . 3–14
3.10.2 Electric Control Cabinet with Engine Display Thom - Katt,
King - Katt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–15
3.10.3 Electric Control Cabinet Vehicle Series (VS) with PTO
(Power Take - Off) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–17
A820090_TOC_0806D I
Table of Contents
3.10.4 Electric Motor Start Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–19

3.10.5 Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–20
3.11 PTO Controls (Only For VS PTO Models) . . . . . . . . . . . . . . . . . 3–21
3.12 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–22

3.12.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–22
3.12.2 System Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–22
3.12.3 System Filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–22
3.12.4 Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–23
3.12.5 Main Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–24
3.12.6 Secondary Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–25
3.12.7 Main Control Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–26
3.12.8 Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–27
3.12.9 Spool Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–28
3.13 Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–29

3.13.1 Delivery Cylinder Pump System . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–29
3.13.2 S-Tube Shifting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–30
3.13.3 Auxiliary System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–31
3.14 Hopper Grate Cutout Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–31
3.15 Centralized Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . 3–33
3.16 Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–34

3.16.1 Auto-Lube System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–34
3.16.2 Cable and Radio Remote Control Unit . . . . . . . . . . . . . . . . . . . . . . 3–35
Cable Remote TK 12V (Optional) . . . . . . . . . . . . . . . . . . . . . . . 3–35
Cable Remote RPM/VOL TK 12V (Optional) . . . . . . . . . . . . . 3–36
3.16.3 Radio remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–37
Radio Remote with ON/OFF/REV/RPM/VOLUME
(Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–37
3.16.4 Hydraulic Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–38
3.16.5 Remixer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–39
3.16.6 Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–40
3.16.7 Cylinder Stroke Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–41
3.16.8 Vibrator Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–42
3.16.9 Throttle Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–43
3.16.10 Volume Control Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–44
II A820090_TOC_0806D
Table of Contents
4 Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1
4.1 Towing of Trailer Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2
4.2 Driving of Vehicle Series Models . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2
4.3 Moving of Skid Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2
5 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1
5.1 Preliminary Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2
5.2 Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2

5.2.1 Pre-Operation Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2
5.2.2 Trailer or Chassis Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4
5.2.3 Delivery System Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4
5.3 Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–6

5.3.1 Start-Up of Concrete Pump Powered by a Diesel Engine . . . . . . 5–7
5.3.2 Start-Up of Concrete Pump Powered by the Vehicle’s PTO . . . . . 5–9
5.3.3 Start-Up of Concrete Pump Powered by an Electric Motor . . . . 5–11
5.3.4 Checking the Hopper Grate Safety Cutout Device . . . . . . . . . . . . 5–13
5.3.5 Priming of Concrete Pump and Delivery System . . . . . . . . . . . . . 5–14
5.4 Emergency Stop Button Locations . . . . . . . . . . . . . . . . . . . . . . . 5–15
5.5 Maintenance During a Pour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–17

5.5.1 Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–17
5.5.2 Operational Tips and Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . 5–18
5.5.3 Avoiding Blockages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–19
5.5.4 Clearing a Blockage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–20
5.6 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–21
5.7 Shutting Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–23
5.8 Pumping Concrete with the Emergency Stroke Change Kit

(Diesel Engine Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–24
A820090_TOC_0806D III
Table of Contents
6 Maintenance . . . . . . . . . . . . . . . . . . . . . . . 6–1
Lock Out — Tag Out Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–2
6.1 Maintenance Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3

6.1.1 Hydraulic Oil Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5
6.2 Recommended Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–6

6.2.1 Hydraulic Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–7
Hydraulic Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–7
Oil / Filter Change Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–7
6.2.2 Oils and Greases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–7
6.3 Inspecting the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–9
6.4 Adding Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–10
6.5 Lubricating the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–11

6.5.1 Lubrication Points for Thom--Katt, Katt--Kreter, King--Katt and
VS Concrete Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–11
6.5.2 Lubrication Points for TKS Skid--Mounted Concrete Pumps . . . 6–13
6.6 Replacing the Return Oil Filter Element . . . . . . . . . . . . . . . . . . 6–14
6.7 Changing the Hydraulic Fluid;

Cleaning the Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–15
6.7.1 Draining the Hydraulic Oil Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–16
6.8 Checking and Adjusting Hydraulic System Pressures . . . . . 6–17

6.8.1 Checking Standby Pressure of The Main Hydraulic Pump . . . . . 6–18
6.8.2 Adjusting Standby Pressure of The Main Hydraulic Pump . . . . . 6–18
6.8.3 Checking Main System and Relief Pressure . . . . . . . . . . . . . . . . . 6–19
6.8.4 Adjusting Main System and Relief Pressure . . . . . . . . . . . . . . . . . 6–20
6.8.5 Checking S-Tube Shift Circuit Pressure . . . . . . . . . . . . . . . . . . . . . 6–21
6.8.6 Adjusting S-Tube Shift Circuit Pressure . . . . . . . . . . . . . . . . . . . . . 6–23
6.8.7 Adjusting Remixer Relief Pressure . . . . . . . . . . . . . . . . . . . . . . . . . 6–24
6.9 Adjusting Proximity Switch Settings . . . . . . . . . . . . . . . . . . . . . 6–25
6.10 Replacing Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–27

Proximity Switch Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–27
6.11 Performing Maintenance on the Accumulator . . . . . . . . . . . . . 6–28

6.11.1 Checking Accumulator Pre-Charge Pressure . . . . . . . . . . . . . . . . 6–31
6.11.2 Decreasing Accumulator Pressure . . . . . . . . . . . . . . . . . . . . . . . . . 6–32
IV A820090_TOC_0806D
Table of Contents
6.11.3 Increasing Accumulator Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . 6–33

6.11.4 Replacing Accumulator Bladder . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–35
6.12 Function Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–39
6.13 Hydraulic Hose Inspection and Replacement . . . . . . . . . . . . . 6–41
6.14 Delivery Piston Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 45

6.14.1 Piston replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 47
Removing a piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 48
Fitting a piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 49
6.15 Replacing the S--Transfer Tube . . . . . . . . . . . . . . . . . . . . . . . . . . 6–51

Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–51
6.15.1 Dismantling the S--transfer tube bearing . . . . . . . . . . . . . . . . . . . . 6–51
6.15.2 S--transfer tube bearing gasket set . . . . . . . . . . . . . . . . . . . . . . . . . 6–52
6.15.3 Removing the S--transfer tube shaft bearings . . . . . . . . . . . . . . . . 6–53
6.15.4 S--transfer tube shaft bearing gasket set . . . . . . . . . . . . . . . . . . . . 6–56
6.15.5 Removing the wear plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–58
6.15.6 Removing the S--transfer tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–60
6.15.7 Replacing the wear sleeve on the S--transfer tube . . . . . . . . . . . 6–61
6.15.8 Fitting the wear plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–62
Machines with 5--bolt wear plate . . . . . . . . . . . . . . . . . . . . . . . . 6–63
Machines with 2--bolt wear plate . . . . . . . . . . . . . . . . . . . . . . . . 6–64
6.15.9 Replacing the seal ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–65
6.15.10Fitting the S--transfer tube bearing . . . . . . . . . . . . . . . . . . . . . . . . . 6–66
6.15.11 Wear sleeve and collared washer . . . . . . . . . . . . . . . . . . . . . . . . . . 6–66
6.15.12Mounting the switch lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–67
6.16 Adjusting the S--Transfer Tube . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 69

6.16.1 Shutting down the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 69
6.16.2 Starting up the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 70
6.16.3 Set the gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 70
6.16.4 Set the switching overlap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 74
Wear plate with wear ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 74
Wear plate with sample markings . . . . . . . . . . . . . . . . . . . . . 6 — 76
6.16.5 Switching overlap on fully hydraulic control (VHS) . . . . . . . . . . 6 — 78
6.17 Measuring the Wall Thickness

(Machines with S--transfer tube) . . . . . . . . . . . . . . . . . . . . . . . 6 — 81
6.17.1 S--transfer tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 83
6.17.2 Measuring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 84
A820090_TOC_0806D V
Table of Contents
7 Troubleshooting Guide . . . . . . . . . . . . . . 7–1

7.1 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–2
7.2 Hydraulic Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–3
7.3 Main Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–3
7.4 Secondary Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–4
7.5 Control Panel Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–4
7.6 Hydraulic Drive Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–5
7.7 S-Tube Shifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–7
7.8 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–8
7.9 Remixer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–8
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
VI A820090_TOC_0806D
1 Guide to the Operating Instructions
In this chapter you will find notes and information that will help you use these Operating
Instructions. Do not hesitate to contact us if you have any queries:
Putzmeister America, Inc.

Customer Support Group
1733 90th Street
Sturtevant, WI 53177
USA
24 Hr Customer Support: 1-800-890-0269
FAX: 1-262-884-7259
On the Web: www.putzmeister.com
or the Distributor or Dealer that looks after you.
Address:
Telephone:
Telefax:
e-mail:
A820090_01_0806D 1–1
Guide to the Operating Instructions
1.1 Foreword
These Operating Instructions are intended to familiarize you with the machine and to assist in the
proper use of the machine in various possible applications.
The Operating Instructions contain important information on how to operate the machine safely,
properly and economically. Observing these instructions helps to avoid danger, to reduce repair
costs and downtimes, and to increase the reliability and service life of the machine.
The Operating Instructions must be supplemented by the respective local, state and federal laws
and regulations for accident prevention and environmental protection.
The Operating Instructions must always be available wherever the machine is in use.
These Operating Instructions must be read and applied by any person who carries out work with
and on the machine such as:
• Operation, including setting up, troubleshooting in the course of work, or tearing down the
machine;
• Service, (maintenance, inspection, repair)
• Transport.
In addition to the Operating Instructions and relevant rules and regulations for accident
prevention and environmental protection at the job site and machine operation.
Should you have any questions following your study of the Operating Instructions, the Branch or
Agency serving you, or Putzmeister America in Racine, WI will be happy to give you more
information.
When corresponding, please have the machine model and the machine number available at hand.
All product descriptions, illustrations and specifications were in effect at the time the manual was
released for printing. Putzmeister America, Inc. reserves the right to make changes in design or to
make additions to or improvements in its products without obligation to install such equipment on
products previously manufactured.
The contents of this document may not be reproduced, even in part, without our written
permission. All technical data, drawings, etc. are protected by copyright.
© Copyright by Putzmeister America, Inc. 2008
1–2 A820090_01_0806D
1.2 Icons and Symbols

The following icons and symbols are used in the Operating Instructions:
NOTICE Particular information regarding the proper use of the machine is

introduced with the icon illustrated, the word Notice printed in bold, and
a line. The associated text is printed in bold and ends with another line.
CAUTION
Particular information, rules, or precautions intended to alert against
unsafe practices or potentially hazardous situations which, if not avoided,
could result in minor or moderate equipment damage. It is introduced with
the icon illustrated, the word Caution printed in bold, and a line.
The associated text is printed in bold and ends with another line.
WARNING
potentially hazardous situations which, if not avoided, could result in
death or serious personal injury and equipment damage. It is introduced
with the icon illustrated, the word Warning printed in bold, and a line. The
associated text is printed in bold and ends with another line.
DANGER
imminently hazardous situations which, if not avoided, will result in death
or serious personal injury and equipment damage. It is introduced with the
icon illustrated, the word Danger printed in bold, and a line. The associated
text is printed in italics and ends with another line.
A820090_01_0806D 1–3
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1–4 A820090_01_0806D
2 Safety Regulations
Putzmeister America cannot anticipate every possible circumstance that might involve a potential
hazard. The warnings in this manual are therefore not all inclusive. If a procedure, tool, device, or
work method not specifically recommended by Putzmeister is used, you must satisfy yourself that it
is safe for you and others. You should also ensure that the machine will not be damaged or made
unsafe by the procedures you choose.
Each Thom-Katt has undergone a thorough Quality Control inspection at the factory. The design
incorporates built-in safety features, however it can be potentially dangerous in the hands of untrained
or careless operators.
Knowing the characteristics of the machine and function of the controls is important for safe, proper
operation, and use. Becoming familiar with the controls and practices of concrete pumping will result
in efficient and smooth pumping.
This topic: Starts on page:

2.1 Personnel Qualifications 2–2
2.2 Safety Regulations 2–2
A820090_02_0806D 2–1
Safety Regulations
2.1 Personnel
Qualifications
Only qualified personnel must be allowed to operate, repair, or troubleshoot the Thom-Katt:
• A qualified operator is one who has read and understood the instructions in this manual and is
thoroughly familiar with the operating characteristics and limitations of the machine.
• Qualified operators must:
- Know and follow all decals and operating instructions.
- Understand and obey all applicable Local and Government statutes and regulations applying to
safe operation and use of concrete pumping machines.
- Report any damage, defects, problems, or accidents to their supervisor immediately.
• Repair and adjustments must only be made by qualified personnel.
• All personnel assigned to repair or troubleshoot the Thom-Katt must be thoroughly familiar with and
understand the job they are about to do. If in doubt, use extreme caution and obtain assistance from
other trained/qualified personnel. Problems may arise that seem singular but may be due to several
causes.
2.2 Safety Regulations

All personnel operating, assembling, transporting, or maintaining a Thom-Katt should be aware of
and comply with the following safety regulations:
• No modification is to be made to the machine without prior written consent of the Putzmeister
Technical Support or Engineering Department.
• Operators and anyone near the machine must wear appropriate clothing and protective equipment
(i.e., a hard hat, safety glasses, hearing protection, and safety shoes) required by Federal, State, local
and job site regulations. Wearing loose, flapping clothing, neck ties, rings, and wrist identity chains is
dangerous and must be prohibited. Hearing protection OSHA requirements are listed in ”29 CFR Ch.
XVII Section 1910.95 Occupational Noise Exposure,” which can be found at www.osha.gov.
• Do not operate the unit unless it has been leveled and stabilized.
• Do not operate a malfunctioning unit.
• Keep decals and operating instructions legible and readable.
• Make sure safety devices are in good operating condition.
• Do not clean, oil, adjust, or service unit while it is operating.
• Use extreme caution when handling delivery system. Some Thom-Katts are capable of delivering up
to 1500 psi. Pressure can remain in the delivery system even after the unit is shut down.
• Never remove the hopper grate cover when the pump is in operation. It protects against accidental
contact with the remixer shaft and other moving parts inside the hopper.
• During normal operation, never enter the hopper with any part of your body; it is a danger area and
physical injury can occur, even if the engine is stopped.
• Do not stand on the hopper grate.
• If repair or other work must be performed inside the hopper, ensure that engine is OFF and
accumulator pressure reads zero. The system uses a hydraulic accumulator which contains a stored
2–2 A820090_02_0806D
Safety Regulations
charge of high pressure oil to shift the S-tube. Stop engine, turn ignition key to OFF and wait 10--15
seconds until the accumulator pressure gauge reads zero.
• Since hydraulic oil systems can be dangerous, know the circuit you are repairing. It may contain high
pressure and injury could occur. If in doubt, stop the machine and allow sufficient time for the oil
pressure to decrease to zero. Check pressure gauges to confirm that they read zero.
• Do not open the concrete delivery system without relieving the pressure. Pressure can be relieved by
reversing the pump and pumping backward.
• When hydraulic cylinders are used to hold loads, do not loosen fittings without mechanically
supporting the load. Loosening of fittings may result in high pressure fluid leaks and movement of the
cylinder.
• Do not fill the fuel tank while the engine is running or hot. Avoid the possibility of spilled fuel, which
may cause a fire.
• If a fuel spill occurs, do not restart the engine until all spilled fuel has been cleaned up.
• Do not pour material into hopper without grate in place. Operator must monitor material being
dumped in hopper, watching for unmixed or dry concrete, sticks, pieces of metal and other foreign
objects.
• If machine is to be left unattended on a job site, secure it from unauthorized use or movement.
• Clear area before activating outriggers.
• Ensure that a proper level is maintained in the hydraulic oil tank. Oil level below minimum can cause
hydraulic pump and system damage.
• Ensure that the work site has adequate lighting for safe operation.
A820090_02_0806D 2–3
Safety Regulations
2–4 A820090_02_0806D
3 General Technical Description
This chapter describes the components and assemblies on this machine and describes how they
function. Please note that available options will also be described. The machine card will tell you
whether the option described is fitted to your machine.

3.1 Principles of Operation 3--2
3.2 Flat Pack Assembly 3–3
3.3 Thom--Katt, Katt--Kreter, and King--Katt Series Trailer-Mounted
3--4
Overview Diagram
3.4 TKS Skid--Mounted Overview Diagram 3--5
3.5 Vehicle Series (VS) Overview Diagram 3--6
3.6 Vehicle Series PTO (VS PTO) Overview Diagram 3--7
3.7 Machine Rating Plate 3–8
3.8 Symbols for the Control System 3--9
3.9 Electrical System 3--11
3.10 Electric Control Cabinet 3–12
3.11 PTO Controls (Only For VS PTO Models) 3--21
3.12 Hydraulic System 3--22
3.13 Hydraulic Circuit 3--29
3.14 Hopper Grate Cutout Device 3--29
3.15 Centralized Lubrication System 3--33
3.16 Optional Equipment 3--34
A820090_03_0806D 3–1
General Technical Description
3.1 Principles of Operation

The Thom-Katt, Katt-Kreter and King-Katt is a hydraulically and electrically operated concrete
pump that is designed to pump wet concrete through a delivery system of pipes and hoses. It can
be mounted on a truck, trailer, or skid frame and is of rugged construction and durable design,
enabling the unit to pump even the harshest mixes within its published ratings/specifications.
Normal operation is controlled at the conveniently located control panel on the unit. A versatile
multi-function cable remote control for start, stop, and reverse enables the unit to be controlled
100 feet (30m) away from the machine. A radio remote control unit is available as an option.
A diesel engine (mounted on a truck or trailer), or an electric motor operating at a preset RPM,
drives the main hydraulic pump. This direct connected variable displacement, load sensing
hydraulic pump is used to power the two hydraulic cylinders, which in turn drive two delivery
cylinder pistons. An S-tube design delivery system is employed and automatically shifts from one
delivery cylinder to the other for a continuous flow of material through the delivery system. A
standard or “super” hopper is an integral part of each machine.
On a unit with no options, a single-stage secondary hydraulic pump is used. With a remixer, water
pump, or hydraulic outrigger option, a double-stage secondary hydraulic pump is used. The first
stage of the pump is designed to work in conjunction with an accumulator to produce the volume
and pressure required for shifting of the S-tube. The second stage produces the volume and
pressure for the options.
In the pumping cycle, a continuous flow of material through the delivery line is produced by the
alternating operation of the delivery cylinder pistons. This is accomplished as one of the
hydraulic cylinders which has the delivery cylinder open to the hopper retracts, pulling with it the
piston of the delivery cylinder. At this point the concrete is drawn or sucked into the delivery
cylinder from the hopper. Upon reaching its full retracted position, an electrical signal from a
proximity switch sends a signal to the S-tube shift valve. The S-tube now shifts to the loaded
delivery cylinder. The hydraulic cylinder extends and the delivery cylinder piston pushes the
concrete through the S-tube, out the discharge and into the delivery line. The cycle is repeated
with the other cylinder providing uninterrupted concrete flow.
The flat pack as shown in Illustration 3-1, has a water box which performs the following
functions: (1) cools the delivery pistons and piston rods, and (2) rinses the inner wall of the
delivery cylinders.
3–2 A820090_03_0806D
3.2 Flat Pack Assembly

The flat pack assembly consists of the hopper, S-tube, delivery cylinders, water box, drive
cylinders and other components as shown in Illustration 3-1 below:
15
1
2
14
9
3
4
5
7
8
9
10
11
12
13
A820090_03_0806D 1
Illustration 3 - 1: Flat Pack Assembly
1 S - tube 9 S-tube shift cylinders

2 Adapter 10 Metal screen
3 Coupling 11 Delivery cylinders
4 Hopper 12 Water box
5 Agitator safety cut - out switch 13 Drive cylinders
6 Remixer (optional) 14 Cover for S - tube shift cylinders
7 Hopper clean - out door 15 Folding splash guard
8 Manual lube kit
A820090_03_0806D 3–3
3.3 Thom−Katt, Katt Kreter and King Katt Series Trailer−Mounted Overview Diagram
A Thom-Katt, Katt Kreter and King-Katt series trailer-mounted model is powered by a diesel
engine. The pumping unit is mounted on a towable trailer, which has a hitch and brake system
(hydraulic or electric):
10
4 11
3
2 12
1
14 13 A820090_03_0806D 2
Illustration 3 - 2: TK&KK Series Trailer-Mounted Concrete Pump
1 Diesel engine 8 Hydraulic control block and accumulator

2 Main hydraulic pump 9 Air Filter
3 Hydraulic system oil tank (with level indicator & 10 Battery
thermometer)
4 Throttle, volume control, and pressure gauges 11 Machine rating plate
5 Outrigger leg LH/RH (hydraulic optional) 12 Trailer (Single or Tandem Axle)
6 Control box (with engine display if equipped) 13 Box for Operating Instruction
7 Flat pack assembly 14 Fuel tank
3–4 A820090_03_0806D
3.4 TKS Skid−Mounted Overview Diagram

A Thom-Katt TKS series skid-mounted model is powered by an electric motor (50HP 230/460V
60Hz Y-Delta or 70HP 460/230V 60Hz Y-Delta). The pumping unit is mounted on a skid frame
which has lifting eyes for job site mobility:
11
10
12
9
9
8
13
7
6
5
4
3
2 14
1
A820090_03_0806D 3
Illustration 3 - 3: TKS Series Skid-Mounted Concrete Pump
1 Electric motor 8 Agitator control valve

2 Hydraulic oil cooler 9 Hopper clean - out door
3 Machine rating plate 10 Hopper
4 Hydraulic oil filter 11 Folding splash guard
5 Hydraulic pressure gauges 12 Lifting eyelet
6 Pump control box (all pump functions) 13 Motor starter control box (electric models only)
7 Hydraulic oil level & temperature 14 Flat pack assembly
A820090_03_0806D 3–5
3.5 Vehicle Series (VS) Overview Diagram

A vehicle series (VS) model is powered by a diesel engine. The pumping unit is mounted on a
truck chassis as shown below:
1 2 3 4 5 6
7 8 9 10 11
A820090_03_0806D 4
Illustration 3 - 4: Vehicle Series (VS) Concrete Pump
1 Water tank & water pump 7 Machine rating plate on passenger’s side
2 Pipe rack (optional) 8 Truck fuel tank
3 Hood 9 Tool box (driver and passenger side)
4 Diesel engine 10 Battery on driver’s side
5 Electric control cabinet; hydraulic system oil
11 Tow hook
tank
6 Flat pack assembly
3–6 A820090_03_0806D
3.6 Vehicle Series Power Take−Off (VS PTO) Overview Diagram

A vehicle series power take-off (VS PTO) model is powered from the truck engine, thru a Power
Take-Off (PTO). The pumping unit is mounted on a truck chassis as shown below:
1 2 3 4 5 6
7 8 9 10 11 12 A820090_03_0806D 5
Illustration 3 - 5: Vehicle Series (VS) PTO Concrete Pump
1 PTO Controls 7 Truck battery

2 Water tank & water pump 8 Machine rating plate on passenger’s side
3 Oil cooler 9 Truck fuel tank
4 Pipe rack (optional) 10 Transfer case
5 Hydraulic system oil tank and control panel 11 Tool box (driver and passenger side)
6 Flat pack assembly 12 Tow hook
A820090_03_0806D 3–7
3.7 Machine Rating Plate

The machine rating plate contains all the important information about the unit (i.e. model and
serial number). Keep a copy of the information handy for future reference.
8 9
1 10
2 11
3 4 12
5 13
A820090_03_0806D 6
Illustration 3 - 6: Machine Rating Plate
1 Serial Number (machine number) 8 Gross vehicle weight rating (lb)

2 Model Designation 9 Gross axle weight rating (lb)
3 Model year 10 Tire size (e.g., LT235/65 R16 TW) (Truck, trailer
series)
4 Maximum engine RPM 11 Rim size (e.g., 16 X 6) (truck, trailer series)
5 Maximum hydraulic pressure (PSI) 12 Cold inflation pressure (PSI) of tires (e.g., 80 PSI)
(truck, trailer series)
6 Maximum concrete pressure (PSI) 13 Vehicle identification number
7 Manufacturing date
3–8 A820090_03_0806D
3.8 Symbols for the Control System

This section gives you a summary of the symbols used for control actions.
NOTICE Some TK models may be equipped with an engine display module. For
more information, please refer to the Technical Enclosure “Deutz Display”
included with this manual.
3.8.1 Engine
1 2 3 4 5 6 7 8
A820090_03_0806D 7
Illustration 3 - 7: Symbols used for Engine Functions
1 Diesel engine on 5 Engine speed in general

2 Diesel engine off 6 Engine speed
3 Charge monitor 7 Increase engine speed
4 Engine oil pressure 8 Reduce engine speed
3.8.2 Electrical System
1 2 3 4 5 6 7 8
A820090_03_0806D 8
Illustration 3 - 8: Symbols used for Electrical System
1 On - Off 5 EMERGENCY SHUT - DOWN

activated
2 On 6 Operating position (local control)
3 OFF 7 Remote control in general
4 Activate EMERGENCY 8 Plug in remote control
SHUT - DOWN
A820090_03_0806D 3–9
3.8.3 Concrete Pump
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
17
A820090_03_0806D 9
Illustration 3 - 9: Symbols used for Concrete Pump
1 Pump On/Off 10 Agitator in general

2 Pump on 11 Agitator clockwise rotation
3 Pump off 12 Agitator counterclockwise rotation
4 Reverse pumping 13 Agitator safety cutout
5 Stroke change - over 14 Vibrator in general
6 Increase - reduce pumping rate (using 15 Vibrator On
rotary controller)
7 Increase - reduce pumping rate (using 16 Vibrator Off
toggle switch)
8 Increase output 17 Water pump
9 Reduce output
3–10 A820090_03_0806D
3.9 Electrical System

Refer to the “Electrical Schematic” in the Technical Data Section for a complete description of
the electrical system.
NOTICE A 12 volt deep cycle battery, which is kept charged by an alternator,

provides power to all Thom-Katt electrical components. Please remember
the following information concerning the battery and ignition key-switch:
– It is important that the battery is kept fully charged. Although the
battery may have sufficient charge to start the diesel engine, it may not
have sufficient capacity to operate the system.
– The ignition key-switch must remain on during pump operation to
provide electric power to the pump controls.
– Leaving the ignition key-switch on with the diesel engine shut down
will discharge the battery.
The electrical system for Thom-Katt, Katt-Kreter, and King-Katt powered by a diesel engine
consists of the alternator on diesel engine, battery, electric control cabinet, and optional
equipment (e.g., cable remote control, radio remote control receiver and transmitter, vibrator, etc.)
requiring electrical power.
The electrical system for Thom-Katt Skid models with electric motor consists of a motor start
box, electric control cabinet, and electrically powered optional equipment (such as, cable remote
control, radio remote control receiver and transmitter, vibrator, etc.).
The electrical system for the Vehicle Series (VS) and Vehicle Series with Power Take-Off (PTO)
consists of the alternator on the Thom-Katt diesel engine or truck diesel engine, battery, electric
control cabinet, and electrically powered optional equipment.
For more information, please refer to the electrical schematic diagram in the Technical Data
section of this manual.
A820090_03_0806D 3–11
3.10 Electric Control Cabinet Thom−Katt, Katt−Kreter, VS (Vehicle Series)

The electric control cabinet is located above the hydraulic oil tank on all units. For more
information, please refer to the Spare Parts Page and the electrical schematic that is included with
this manual.
1 2 3
16
4 5 6 7
8
9
13 RP 11 12
M
10
17 ENGINE
START
14 15
ENGINE ACCUMULATOR MAIN SYSTEM VOLUME

THROTTLE PRESSURE HYDRAULIC PRESSURE CONTROL
21
18 19 20
A820090_03_0806D 10
Illustration 3 - 10: Hydraulic System Oil Tank and Electric Control Cabinet
1 Hour meter - Records the number of engine operating hours.
2 Pump running indicator (green) - If illuminated, pump is running OK.
3 Reverse pumping on indicator (green) - Illuminates when pumping in reverse.
4 Pump on/off toggle switch - Push up to turn pump on or push down to turn pump off.
5 Pressure test and stroke change switch - Momentary toggle switch (i.e., it returns to center position
when released):
- Pressure Test function: Push up and hold to complete the pump stroke. At the end of the stroke,
the pump will pressure out to the maximum pressure. The maximum pressure can be read on the
main system hydraulic pressure gauge.
- Stroke Change function: Temporarily push up to change the drive cylinder direction and shift the
S - tube (i.e., change from pumping one cylinder to the other).
6 Reverse pumping toggle switch - Push up to have pump to operate in reverse direction or push
down to have pump operate in forward direction.
7 Electric throttle switch (optional) - Move up to increase or down to decrease engine throttle speed.
Engine speed is maintained when this toggle switch is released.
NOTE: On some TK and VS units, this switch may be used to turn on the cooler fan.
3–12 A820090_03_0806D
CAUTION
Whenever outriggers or accessories are operated, maximum engine RPM should
be used. Engine speed should not be used to “feather” operating functions.
Operating at low engine speeds can cause lack of lubrication and overheating,
resulting in damage to hydraulic components.
8 Engine tachometer - Monitors the engine speed in RPM (e.g., 2 x 1000 = 2000 RPM). Adjustment of
RPM can be done by the engine throttle control noted below. (Not present on TK electric models)
9 Emergency stop button - Push in this button to stop diesel engine in emergency situations. To
release knob, twist knob clockwise.
10 Emergency stop (E-stop) indicator (red) - If illuminated, an emergency shut-down has been
activated.
11 Alternator fault indicator (red) - Turns on when the alternator output is not sufficient to keep the
battery charged.
12 Engine oil pressure indicator (red) - Turns on if the engine oil pressure drops to an insufficient level.
If this light turns on, turn off engine and check engine oil level immediately.
13 Engine coolant temperature gauge - Indicates temperature of engine coolant on all units, except for
the TK40 and TK electric models.
14 Local/remote control switch - This switch should be locked in either the “local” or “remote” position.
In the “local” position, the concrete pump operation is controlled by the switches on the electric
control cabinet (see items 5, 6, 9, and 21) . In the “remote” position, the switches on the electric
control cabinet are disabled and the concrete pump operation is controlled by the switches or buttons
on the cable/radio remote control unit. For operation of the remote control unit, refer to the “Cable
and Radio Remote Control Unit” section.
15 Power key-switch and engine start push button - A 3-position key switch is used to control electrical
power to the control cabinet. An ENGINE START push button is used for engine start. Turn key on
and press ENGINE START push button to start engine. Turn key off to stop engine. To aid in cold
weather starting on certain engines (e.g., Perkins), turn key switch clockwise and hold in “heater”
position for 15 seconds prior to engine starting (key will spring return to “run” position when
released). (Engine start push button not present on TK electric models)
16 Auto-lube switch (optional) - Push in to manually activate the auto-lube system.
17 Remote control receptacle - The radio receiver or cable remote control cord is plugged into this
socket. When connecting or disconnecting the radio/cable remote control cord, ensure the pump
switches on the control cabinet and remote control unit are in the OFF position. This will prevent
unintended operation of the machine.
18 Engine throttle control - Turn knob counterclockwise to increase engine speed or clockwise to
decrease engine speed. After desired speed is set, turn knob located against shroud clockwise to
hold speed. This prevents accidental release. To return throttle to idle position, turn same knob to
release position and press center button on control.
19 Accumulator pressure gauge - This 0 - 3000 PSI (205 BAR) pressure gauge indicates the pressure
for the shifting cylinder of the S-tube and pilot valves.
20 Main system hydraulic pressure gauge - This 0 - 6000 PSI (410 BAR) gauge indicates the hydraulic
pressure required to pump the material.
21 Volume control - Adjusts the output discharge volume of the delivery cylinders, which in turn is
controlled by the hydraulic pump. Turn knob counterclockwise to increase volume or clockwise to
decrease volume. Do not vary the pump output by varying engine speed. Optimum engine
horsepower and pump flow are attained at the rated engine speed.
A820090_03_0806D 3–13
3.10.1 Deutz Engine Display and Control Module (if equipped)

The Deutz engine display and control module is located on the side of the hood next to the
control box. The module has a key switch used to start the engine, an engine speed pushbutton
selector, Deutz display with menu selection keys, and self-test/fault indicator LEDs.
For more information, please refer to the Spare Parts Page and the electrical schematic that is
included with this manual.
5
1
2 A820090_03_0806D 11
Illustration 3 - 11: Deutz Engine Display and Control Module (if equipped)
1 Power key - switch and engine start - A 4 - position key switch is used to control electrical power to
the control box. Turn key to START position to start engine. Turn key to OFF position to stop engine.
2 Engine speed selector - A pushbutton switch used to change the engine speed. Press the
pushbutton to the UP position to increase engine speed. Press the pushbutton to the DOWN position
to decrease engine speed.
3 Deutz display - Digital display of the engine status. For more information, please refer to the
Technical Enclosure “Deutz Display” included with this manual.
4 Self - test, fault indicators - LED indicators used to indicate engine status during initial self - test or
fault condition.
5 Function keys - Used with graphical menu structure. For more information, please refer to the
Technical Enclosure “Deutz Display” included with this manual.
Note
NOTICE The Deutz display and module will not control or operate the pump. To operate the
pump, use the control box functions shown in the previous section.
3–14 A820090_03_0806D
3.10.2 Electric Control Cabinet with Engine Display Thom−Katt, King−Katt

Control cabinets with engine display is shown below. For more information, please refer to the
Spare Parts Page and the electrical schematic that is included with this manual.
6 7
5
20 4
19 21
8 9 10 11
23 22
15
12 13 14
3
18 16
2 1 17
ACCUMULATOR MAIN SYSTEM VOLUME

PRESSURE HYDRAULIC PRESSURE CONTROL
24 25 26
A820090_03_0806D 12
Illustration 3 - 12: Control Box with Engine Display (if equipped)

1 Key switch and engine start - A 2 - position key switch is used to start and stop the engine. Turn key to start
(I) position to start engine. Turn key to off (O) position to stop engine.
2 Engine speed selector - A toggle switch is used to change the engine speed. Press the toggle switch up to
the (+ rpm) position to increase engine speed. Press the toggle switch down to the ( - rpm) position to
decrease engine speed.
3 Function keys - Used with graphical menu structure. For more information, please refer to the Technical
Enclosure “Deutz Display” included with this manual.
4 Deutz display - Digital display of the engine status. For more information, please refer to the Technical
Enclosure “Deutz Display” included with this manual.
Note
NOTICE The engine display and module will not control or operate the pump. To operate
the pump, use the pump operation functions on the control box .
5 Hour meter - Records the number of pump operating hours. Engine hours can be seen on the engine
display.
6 Pump running indicator (green) - If illuminated, pump is running OK.
A820090_03_0806D 3–15

9 Pressure test and stroke change switch - Momentary toggle switch (i.e., it returns to center position when
released):
- Pressure Test function: Push up and hold to complete the pump stroke. At the end of the stroke, the pump
will pressure out to the maximum pressure. The maximum pressure can be read on the main system
hydraulic pressure gauge.
- Stroke Change function: Temporarily push up to change the drive cylinder direction and shift the S - tube
(i.e., change from pumping one cylinder to the other).
10 Reverse pumping toggle switch - Push up to have pump to operate in reverse direction or push down to
have pump operate in forward direction.
11 Oil cooler fan switch - Push up switch to turn on the oil cooler fan. Push down to turn off cooler fan.
12 Engine preheat (yellow) LED - If illuminated, indicates that glow plugs have been activated to preheat the
engine prior to starting the engine in cold weather. Preheat engine until preheat LED goes out. Note:
Please refer to the “Start Procedure” for more information on using cold start aid in the engine
manufacturer’s operation manual included with these operating instructions.
13 Engine fault (red) LED - Turns on when an engine fault occurs. For more information on engine faults,
please refer to the engine manufacturers operation manual.
14 Alternator fault indicator (red) - Turns on when the alternator output is not sufficient to keep the battery
charged.
15 Emergency stop (E-stop) indicator (red) - If illuminated, an emergency shut-down has been activated.
16 Emergency stop button - Push in this button to stop diesel engine in emergency situations. To release knob,
twist knob clockwise.
17 Local/remote control switch - This switch should be locked in either the “local” or “remote” position. In the
“local” position, the concrete pump operation is controlled by the switches on the electric control box (see
items 8, 9, 10, 16) . In the “remote” position, the switches on the electric control cabinet are disabled and
the concrete pump operation is controlled by the switches on the cable/radio remote control unit. For
operation of the remote control unit, refer to the “Cable and Radio Remote Control Unit” section on page
3 - 33.
18 Diagnostic plug - Female connector used for troubleshooting and diagnosing electrical components of
engine.
19 Vibrator connector (optional) - Female plug for plugging - in vibrator electrical connection.
20 Vibrator toggle switch (optional) - Push up to turn vibrator on. Push down to turn vibrator off.
21 Dummy plug (1/2 in./12 mm) - Optional equipment.
22 Autolube switch (optional) - Push in to manually activate the auto-lube system.
23 Remote control receptacle - The radio receiver or cable remote control cord is plugged into this socket.
When connecting or disconnecting the radio/cable remote control cord, ensure the pump switches on the
control cabinet and remote control unit are in the OFF position. This will prevent unintended operation of
the machine.
24 Accumulator pressure gauge - This 0 - 3000 PSI (205 BAR) pressure gauge indicates the pressure for the
shifting cylinder of the S-tube and pilot valves.
25 Main system hydraulic pressure gauge - This 0 - 6000 PSI (410 BAR) gauge indicates the hydraulic
pressure required to pump the material.
26 Volume control - Adjusts the output discharge volume of the delivery cylinders, which in turn is controlled by
the hydraulic pump. Turn knob counterclockwise to increase volume or clockwise to decrease volume. Do
not vary the pump output by varying engine speed. Optimum engine horsepower and pump flow are
attained at the rated engine speed.
3–16 A820090_03_0806D
CAUTION
Whenever outriggers or accessories are operated, maximum engine RPM should
be used. Engine speed should not be used to “feather” operating functions.
Operating at low engine speeds can cause lack of lubrication and overheating,
resulting in damage to hydraulic components.
3.10.3 Electric Control Cabinet Vehicle Series (VS) with PTO (Power Take−Off)
17 21 18 19 1 2 3 4 5
6 7 8 9 10
20 12 11 13 14 15 16
A820090_03_0806D 13
Illustration 3 - 13: Electrical Control Cabinet for VS series with PTO
1 Panel power indicator (green) - If illuminated, power is on to control box. Power will remain on only
if the truck parking brake is set, the Pump PTO is engaged, and the truck transmission is in the
proper pumping gear. Some trucks will allow pumping in more than one gear.
2 Pump running indicator (green) - If illuminated, pump is running OK. If flashing, pump is not running.
3 Emergency stop (E-stop) indicator (red) - If illuminated, an emergency shut-down has been
activated.
4 Hydraulic oil over-temperature indicator (red) - This illuminates if hydraulic oil temperature reaches
90_C(194_F).
5 Hour meter - Indicates the time that the concrete pump has been on.
6 Throttle switch - Move up to increase or down to decrease engine throttle speed. Engine speed is
maintained when this toggle switch is released.
A820090_03_0806D 3–17
Note
NOTICE Maximum RPM settings vary according to truck and transmission options. Engine
speed can be adjusted using any of the following throttle controls:
– Cruise control in truck cab
– Throttle control switch on the electric control box
– Throttle control switch on the cable remote control head
7 Pump on/off and reverse pumping toggle switch - Push up once to turn pump on; push up again to
turn pump off. Push down to have pump operate in reverse.
8 Stroke changeover switch - Push up to change the drive cylinder direction and shift the S - tube.
9 Cooler fan on indicator (green) - Illuminates when oil cooler fans are operating.
10 Volume control switch - Adjusts the output discharge volume of the delivery cylinders, which in turn
is controlled by the main hydraulic pump. Push up to increase volume or push down to decrease
volume. Do not vary the pump output by varying engine speed. Optimum engine horsepower and
pump flow are attained at the rated engine speed.
11 Local/remote control switch (locks when in local position)
12 EMERGENCY SHUT-DOWN button - This is the one of four E-stops located on the machine. The
other E-stops are located on the radio (or cable) remote control box, and rear of unit on left and right
side. To permit remote control system operation, twist this button to allow it to pop up and then clear
the E-stop mode using the horn/reset switch (item 14). Push in this button to turn off the remote
control system in emergency situations. Pressing this button will cause the engine throttle to go to
idle and stop all machine functions except cooling fans and water pump. If the emergency still exists,
the malfunction is probably hydraulic and the machine must be disabled by truck engine shutdown or
PTO disengagement.
14 E-stop reset/horn switch - Push to clear the E-stop mode and/or blow the horn. The first press
clears the E-stop. The second and subsequent presses blow the horn.
15 Manual oil cooler fan switch - Turn on to manually activate oil cooler fans.
16 Hydraulic oil temperature gauge - Receives signal from probe at bottom of hydraulic oil cooler.
17 X8 connector for auxiliary power
18 Vibrator on/off switch
19 X7 connector for vibrator - refer to Electric Control Box Schematic
20 X88 connector - refer to Electric Control Box Schematic
21 Auto-lube switch (optional) - Push in to manually activate the auto-lube system.
3–18 A820090_03_0806D
3.10.4 Electric Motor Start Box

On Thom-Katt units with electric motors theres is an electric motor start box. The electric motor
start box is connected to a utility input power source and provides electric power to the electric
motor. On the electric motor start box panel there is one main ‘On/Off’ switch, a second
‘On/Off’ switch, a green ‘START’ push button, a red ‘STOP’ push button, and a green ‘RUN’
pilot light as shown in Illustration 3-13.
2
ON
3 OFF
ON
OFF
4 RUN
START
5
6 STOP
A820090_03_0806D 14
Illustration 3 - 14: Electric Motor Start Box (460V 60Hz Y - Delta)

1 Electric motor starter control box
2 Main power circuit breaker lever - Position this lever to ON to close the main power circuit breaker
(power supply On) or to OFF to open the main power circuit breaker (power supply Off)
3 Main power ‘ON/OFF’ switch - Turns on or off 460V 60Hz input power. When switch is turned to ON
position, the red light on this switch illuminates.
4 Pump ‘RUN’ light - This green pilot light illuminates when the electric motor is running.
5 Electric motor ‘START’ pushbutton - Push this green button to start the electric motor.
6 Electric motor ‘STOP’ pushbutton - Push this red button to stop the electric motor.
DANGER
Electrocution hazard. Line voltage present with machine power off.
A820090_03_0806D 3–19
3.10.5 Power Source

A 12 volt deep cycle battery, which is kept charged by an alternator, provides power to all
Thom-Katt electrical components:
Then power for the Thom-Katt And the diesel engine is

If you have . . .
electrical components is provided by . . . started . . .
The truck battery (mounted next to the truck
A VS PTO model In the truck cab
diesel engine)
A Thom-Katt diesel engine
A separate battery (mounted on the frame) At the control panel
powered model
For Thom-Katt electric models, the utility input power source provides power to all of the
electrical components.
Note
NOTICE Please remember the following information concerning the battery and ignition
key-switch:
– It is important that the battery is kept fully charged. Although the battery may
have sufficient charge to start the diesel engine, it may not have sufficient
capacity to operate the system.
– The ignition key-switch must remain on during pump operation to provide
electric power to the pump controls.
– Leaving the ignition key-switch on with the diesel engine shut down will
discharge the battery.
3–20 A820090_03_0806D
3.11 PTO Controls (Only

For VS PTO Models)
PUMP
DRIVE
A820090_03_0806D 15
Illustration 3 - 15: Power Take-Off (PTO) Switch (Located in Truck Cab)

1 Power take-off (PTO) switch - Controls whether the truck diesel engine provides power for the truck
drive shaft or truck-mounted concrete pump. Move to the DRIVE position to power the truck drive
shaft or to the PUMP position to power the truck-mounted concrete pump.
2 PTO light - This green indicator lamp illuminates when the PTO switch is in the PUMP position.
A820090_03_0806D 16
Illustration 3 - 16: Engine Hand Throttle (Mounted Next to the Control Panel)
1 Engine hand throttle - Manually controls truck engine speed. Pull down to increase engine speed or
push up to decrease engine speed.
A820090_03_0806D 3–21
3.12 Hydraulic System

Refer to the “Hydraulic Circuit” section and the “Hydraulic Schematic” in the Technical Data
Section for a complete description of the hydraulic system.
3.12.1 General
The hydraulic system of the Thom-Katt is an “open center” type. This means that when the
control valves are in the “neutral” position (i.e., hydraulically non-operational) the internal
passages are open, allowing the hydraulic fluid to return to the hydraulic oil tank. With the diesel
engine and hydraulic pump running and no hydraulic controls energized, the oil will pass through
the system on its way back to the hydraulic oil tank.
3.12.2 System Pressures

Refer to the “Checking and Adjusting Hydraulic System Pressures” procedure for proper system
pressure settings.
3.12.3 System Filtration

As shown in the diagram below, the hydraulic system is filtered by a return line filter (single or
double if equipped):
Yellow Red
3
1
Green
2
A820090_03_0806D 17
Illustration 3 - 17: Hydraulic System Filtration Components (TK & VS Models)

1 Hydraulic oil tank
2 Return filter (double if equipped) with a 10 micron replaceable element. Both the main system fluid
and a good portion of the secondary system fluid pass through this filter.
3 Return filter condition indicator gauge - Indicates the differential pressure across the hydraulic return
oil filter assembly. Normal condition is the green range (0 - 29 PSI) and the filter bypasses at 43 PSI
(red range). Elements should be changed if the pressure is in the yellow range (29 - 43 PSI) with the
hydraulic fluid at its normal operating temperature.
3–22 A820090_03_0806D
CAUTION
Damage to hydraulic system can occur. Replace filter elements immediately if the
filter condition indicator is in the red range (43 PSI).
3.12.4 Oil Cooler

The oil cooler has several mounting configurations depending on the model of Thom-Katt. The
purpose is to cool the hydraulic fluid as it leaves the main control block or optional equipment
spool valve before going back to the hydraulic oil tank. Air flow may be provided by the diesel
engine fan or a separate electric or hydraulically operated fan:
1
1
Electric Fan Hydraulic Fan

2 2 A820090_03_0806D 18
Illustration 3 - 18: Oil Cooler
1 Hydraulic fluid outlet 2 Hydraulic fluid inlet
A820090_03_0806D 3–23
3.12.5 Main Hydraulic Pump

The main hydraulic pump, a variable displacement axial piston pump with a swash plate design,
is driven directly by the diesel engine or electric motor power supply. The swash plate is
adjustable and controls the stroke length of the piston, which adjusts the flow. The pump is also
equipped with a pressure compensator and a load (horsepower) limiter device.
2
2
3
3
Bottom View 1 Front View
A820090_03_0806D 19
Illustration 3 - 19: Main Hydraulic Pump
1 Standby pressure adjustment 3 Horsepower limiter

2 Pressure compensation adjustment
NOTICE Please note the following regarding main hydraulic pump adjustments:
– Standby pressure and pressure compensator adjustments can be made
using the “Checking and Adjusting Hydraulic System Pressures”
procedure.
– Horsepower limiter adjustments are made at the factory during a full
load condition. Contact the Putzmeister Service Department if the
horsepower limiter needs to be readjusted.
3–24 A820090_03_0806D
3.12.6 Secondary Hydraulic Pump

The secondary hydraulic pump is an inline gear pump coupled to the main hydraulic pump. On a
Thom-Katt with no options, a single-stage gear pump is used. If a remixer or other options are
selected, then a double-stage pump is used. One stage provides the flow and pressure
requirements for the S-tube shifting circuit (accumulator) and the second stage is used for the
remixer circuit and other options.
1 3
4
4
2
A820090_03_0806D 20
Illustration 3 - 20: Secondary Hydraulic Pumps
1 Single-stage gear pump 3 Double-stage gear pump

2 To S-tube shift cylinder 4 To optional equipment (i.e., remixer, hydraulic
outriggers, water pump, and chemical pump)
A820090_03_0806D 3–25
3.12.7 Main Control Block

The main control block or manifold is mounted on top of the hydraulic tank. It is drilled and
ported to accommodate the relief valves, check valves, solenoid valves, and unload valves used to
enable operation of the concrete pump delivery cylinders as well as the shifting of the S-tube.
8
5
6
2
5
7 3
4
1
9
A820090_03_0806D 21
Illustration 3 - 21: Location of Various Valves and Solenoids on the Main Control Block
1 Main control block
2 Accumulator discharge valve - This 2-position 2-way solenoid operated cartridge valve relieves
accumulator pressure when the pump is stopped and the engine ignition switch is turned off.
3 S - tube shift unload (accumulator charge) valve - This hydraulically piloted cartridge valve adjusts
the S-tube shift circuit pressure.
4 S-tube shift relief valve - This hydraulically piloted cartridge valve adjusts the S-tube shift relief
pressure.
5 S-tube shift pilot solenoid valve - This 2-position 4-way solenoid operated valve controls the S-tube
shift valve.
6 S-tube shift valve - This 2-position 4-way hydraulically piloted valve controls the S-tube shift
cylinders.
7 Main system pilot solenoid valve - This 3-position 4-way solenoid operated valve controls the main
system valve.
8 Main system valve - This 3-position 4-way spring centered hydraulically piloted valve controls the
drive cylinders.
9 Main system relief valve - This adjustable relief valve controls the main system relief pressure.
3–26 A820090_03_0806D
Note
NOTICE The following pressures are adjusted at the main control block using the
“Checking and Adjusting Hydraulic System Pressures” procedure:
– S-tube shift circuit pressure
– S-tube shift relief pressure
– Main system relief pressure
3.12.8 Accumulator
An accumulator, which is used in the S-tube shift circuit, supplies a large volume of oil at a high
flow rate to the appropriate side of the shift cylinder.
A820090_03_0806D 22
Illustration 3 - 22: Accumulator (Located on Top of Hydraulic Oil Tank)

1 Accumulator
2 Accumulator clamp
3 Hydraulic oil tank rear cover
The accumulator consists of the following components:

• An outer shell
• A rubber bladder inside the shell
• A gas port with a gas valve on the shell top
• A fluid port with necessary valves and seals on the shell bottom
The accumulator operates as follows: Upon installation of the accumulator, the bladder is charged
with dry nitrogen gas to the pressure specified on the hydraulic schematic. The gas is used to
inflate the bladder much like a balloon. The hydraulic fluid enters the accumulator through the
fluid port and fills the area at the bottom between the inner wall of the shell and bladder. Because
the fluid volume enters at a higher pressure, the bladder is being compressed. At the appropriate
time in the pump cycle, the S-tube shift valve opens and the fluid is discharged to the shift
cylinder. As soon as the oil is discharged, the accumulator is refilled. The cycle is repeated
continuously.
The accumulator will periodically require recharging, maintenance, or bladder replacement.

Refer to the “Performing Maintenance on the Accumulator” procedure.
A820090_03_0806D 3–27
3.12.9 Spool Valves

One or more spool valves may be used on a particular Thom-Katt unit depending on the hydraulic
powered optional equipment installed (e.g., if the remixer and hydraulic outriggers options are
selected, a triple spool valve will be used; if the remixer and water pump options are selected, a
double spool valve will be used, etc.):
This option . . . Requires this many spool valve control levers . . .

Remixer One
Hydraulic outriggers Two (one for each outrigger cylinder)
Water pump One
Each manually operated directional control spool valve has an adjustable relief valve and one or
more control levers. Each spool valve also has a detented spool (i.e., when the control lever is
moved to a particular direction, it will remain in that position until moved again). The spool
valves are mounted between the hopper and the hydraulic oil tank on the control panel side of the
unit:
4 4 4
5 5 5
1 2 3
A820090_03_0806D 23
Illustration 3 - 23: Various Types of Spool Valves
1 Single spool valve 4 Manual control lever

2 Double spool valve 5 Relief valve adjustment
3 Hydraulic oil tank rear cover
Note
NOTICE For more detailed information on the hydraulically powered optional equipment,
refer to the “Optional Equipment” section.
3–28 A820090_03_0806D
3.13 Hydraulic Circuit

With the engine running, the PUMP switch in the OFF position, and the VOLUME CONTROL
turned in, the hydraulic pump is producing a minimal amount of pressure and flow to enable
lubrication of the pump. The main pump is de-stroked at this time. This condition exists
regardless of whether the engine is at idle or maximum RPM.
Set the engine speed at maximum RPM, with the throttle control on the panel. Open VOLUME
CONTROL, which is the flow control valve. In so doing, the main pump comes on stroke and
produces flow in proportion to the amount the flow control valve has been opened. Turning the
PUMP switch ON activates the S-tube shift and main system valves and directs flow to the
hydraulic cylinders.
A relief valve is incorporated in the main control block to protect the system from excessive
pressures.
3.13.1 Delivery Cylinder Pump System

With the PUMP switch ON, the delivery cylinder pump circuit is energized. The cylinders are
designed to cycle alternately and the cycle is controlled by an electrical signal that is generated at
the end of each material cylinder suction or discharge stroke.
A proximity switch, one for each cylinder is installed in each cylinder. As the piston in the
hydraulic cylinder passes under the proximity switch, an electrical signal is generated which
operates the main system pilot solenoid valve. As the appropriate solenoid coil is energized, it
shifts the pilot valve spool which directs pilot pressure to the main system valve. The main
system valve is then shifted allowing oil to flow to the appropriate hydraulic drive cylinder.
The hydraulic drive cylinders are identical. The main hydraulic system is designed to provide the
flow and pressure to the hydraulic piston or barrel side of the cylinder for extending the rod and
pushing the concrete out the S-tube and discharge.
The hydraulic cylinders are tied together by hoses. The purpose of this is to transfer hydraulic oil
from one to the other during the extension/retraction stroke. As the rod of one cylinder is
extended, oil is pushed out and directed to the rod side of the other forcing the rod to retract. The
retracting rod forces the oil on the opposite side (barrel side) back to the hydraulic oil tank.
It is possible in a no-load condition for there to be excess oil in the hydraulic loop between the
hydraulic cylinders. When this condition exists, the cylinder cannot be totally extended and thus
“short strokes.”
A820090_03_0806D 3–29
To correct this condition, actuate the PRESSURE TEST switch and hold until the cylinder being
extended is bottomed out fully. In normal operation, the check valves installed on both cylinders
are used to remove the excess hydraulic oil from the loop between the cylinders during the
extend/retract cycle. By holding the PRESSURE TEST switch, you are forcing this excess oil
out of the hydraulic loop between the two cylinders and back to the hydraulic oil tank. Once the
extending cylinder is at full stroke, regular operation can continue.
3.13.2 S−Tube Shifting System

Installed at the rear of the main hydraulic pump is the secondary hydraulic pump, which is a
single or double-stage fixed displacement gear pump. The first stage is used for the shifting
circuit and the second stage is used for optional equipment (i.e., remixer, hydraulic outriggers,
and water pump).
With the engine/motor running at full speed, oil flow is circulating through the S-tube shift
circuit. A relief valve is incorporated in the system.
The S-tube shift circuit is energized by activation of the PUMP switch to the ON position and
receipt of the electrical signal from the proximity switches.
As the proximity switch signal is generated, it operates the S-tube shift pilot solenoid valve.
When the solenoid coil is energized, it shifts the pilot valve spool which then directs pilot
pressure to the S-tube shift valve. The S-tube shift valve is then shifted, allowing oil to flow to
the appropriate side of the S-tube shift cylinder.
Since the shifting of the S-tube from one delivery cylinder to the next requires instant pressure
and volume, which cannot be obtained by the system itself, an accumulator is utilized. The
accumulator is automatically filled with the required volume of oil and the compression of the
nitrogen bladder will provide the necessary pressure. The electrical signal from the proximity
switch is also used to open the S-tube shift unload valve, allowing the pressurized oil to go to the
S-tube shift valve and on to the S-tube shift cylinder. The oil on the side of the S-tube shift
cylinders not being pressurized is directed back to the hydraulic oil tank. Immediately after the
accumulator is discharged, the S-tube unload valve closes and the accumulator is refilled.
As a safety to the system, an accumulator solenoid valve is used to automatically relieve the
accumulator pressure when the pump is stopped and the engine ignition switch is turned off.
When the engine ignition switch is in the “off” position, the solenoid valve opens and oil from the
accumulator is exhausted. The oil is directed through an orifice to slow down the exhaust flow.
3–30 A820090_03_0806D
3.13.3 Auxiliary System

The second stage of the secondary hydraulic pump is the auxiliary system that provides the
necessary pressures and flows for operation of the following optional equipment:
• Remixer
• Hydraulic-powered outriggers
• Water pump
3.14 Hopper Grate Cutout Device

The hopper grate cutout device consists of a switching cam and a pressure roller switch. The
switching cam is fastened to the hinge pin of the hopper grate, the pressure roller switch to the
hopper. The pressure roller switch is acted on as soon as you open the hopper grate. This causes
the engine/motor to stop. You must switch the concrete pump off, reset the throttle control to idle,
and re-start the engine/motor.
1 2 3 4
A820090_03_0806D 24
Illustration 3 - 24: Hopper Grate Cutout Device
1 Hopper 3 Switching cam

2 Hopper grate hinge pin 5 Pressure roller switch
CAUTION
The pressure roller switch must always be clean and free to move. In addition, the
pressure roller switch must always be in contact with the switching cam. If the
pressure roller switch is defective, the hopper grate cutout device may not
function, or the diesel engine may stop during pumping operations.
A820090_03_0806D 3–31
WARNING
BEFORE LIFTING HOPPER GRATE TO WORK ON CONCRETE PUMP, VERIFY
THAT HOPPER GRATE CUTOUT DEVICE IS WORKING PROPERLY BY
PERFORMING THE FOLLOWING STEPS: (1) While concrete pump is ON, reach
hand beneath cutout cover and push switch up (refer to diagram below). DO NOT
ATTEMPT TO RAISE HOPPER GRATE. (2) Verify that engine/motor stops and
concrete pump turns OFF.
Hopper grate cutout cover,

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

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

when hopper grate is OPEN. In this po−
sition, the concrete pump should auto−
matically turn OFF.
A820090_03_0806D 25
Illustration 3 - 25: Checking the Hopper Grate Safety Cutout Device
3–32 A820090_03_0806D
3.15 Centralized Lubrication System

The centralized lubrication system delivers grease from a centralized lubrication nipple strip via
supply lines to all lubrication points of the pump which are difficult to access.
6 1
2
4
5
8
A820090_03_0806D 26
Illustration 3 - 26: Centralized Lubrication System
1 Lubrication nipple strip 5 Lubrication nipples

2 Upper s-tube shift cylinder bearings 6 S-tube bearing
3 S-tube shaft bearing 7 Remixer shaft bearings
4 Lower shift cylinder bearings 8 Grease gun
A820090_03_0806D 3–33
3.16 Optional Equipment
3.16.1 Auto−Lube System

An auto-lube system, which is an option for all Thom-Katt models, automatically lubricates all
lubrication points at the interval specified by its timer:
2
1
3
A820090_03_0806D 27
Illustration 3 - 27: Auto-Lube System

1 Auto-lube manual override switch - This push button, which is located on the side of the electric control
cabinet, can be pressed to manually turn on the auto-lube pump, regardless of its timer setting. This switch
illuminates when depressed.
2 Grease block - This block distributes the grease from the auto-lube pump to the lubrication points. The
number of ports on the block vary depending on the equipment installed (i.e., single or double S-tube shift
cylinder, remixer, etc.).
3 Auto-lube pump - This electrically operated pump consists of a pump housing, electric gear motor, timer,
and plastic reservoir with a stirring paddle. The pump automatically turns on and off at the interval specified
by the “on-time” and “off-time” rotary switches. The pump can also be manually turned on by pressing the
manual override switch (item 1).
Note
NOTICE When the auto-lube pump reservoir reaches the “MIN” mark located on the
reservoir, fill it to the “MAX” mark with an appropriate grease listed in the
“Recommended Lubricants” section in the Maintenance chapter.
3–34 A820090_03_0806D
3.16.2 Cable and Radio Remote Control Unit

A cable or radio remote control unit can be connected to the control panel and used to control the
concrete pumping operation:
Note
NOTICE The cable or radio remote control unit will control the concrete pumping operation
only if: (1) It is plugged into the remote control receptacle on the control cabinet
and (2) the “local/remote” switch on the control cabinet is in the “remote”
position.
Cable Remote TK 12V (Optional)
A820090_03_0806D 28
Illustration 3 - 28: Cable Remote Control Unit Diagram

1 Remote control receptacle on side of electric control cabinet
2 Cable remote control unit
3 Emergency stop button - Push in this button to stop concrete pump in emergency situations.
Pushing in this button will not stop the engine/motor. To release knob, twist knob clockwise.
4 Pump on/off toggle switch - Push to right to turn pump on or push left to turn pump off.
5 Reverse pumping toggle switch - Push to right to have pump operate in reverse direction or push to
left to have pump operate in forward direction.
A820090_03_0806D 3–35
Cable Remote RPM/VOL TK 12V (Optional)
A820090_03_0806D 29
Illustration 3 - 29: Cable Remote Control Unit Diagram

1 Remote control receptacle on side of electric control cabinet
2 Cable remote control unit
3 Emergency stop button - Push in this button to stop concrete pump in emergency situations.
– NOTE: Pushing in this button will not stop the engine/motor.
To release knob, twist knob clockwise.
5 Reverse pumping toggle switch - Push to right to have the pump operate in reverse direction or push
to left to have the pump operate in forward direction.
6 Volume increase/decrease toggle switch - Push to right to increase volume or push to the left to
decrease volume.
7 RPM (Speed) increase/decrease toggle switch - Push to right to increase engine speed (RPM) or
push to left to decrease engine speed (RPM).
3–36 A820090_03_0806D
3.16.3 Radio remote control

A radio remote control unit can be connected via radio frequency to the control box to control the
concrete pumping operation:
Note
NOTICE The radio remote control unit will control the concrete pumping operation only if:
(1) the receiver is plugged into the remote control receptacle on the control box
and (2) the “local/remote” switch on the control box is in the “remote” position.
Radio Remote with ON/OFF/REV/RPM/VOLUME (Optional)
1
2
6
3
7
4
A820090_03_0806D 30
Illustration 3 - 30: Optional Radio Remote Control Unit

1 Emergency stop button - Push down button to activate Emergency Stop. Twist to unlock (reset) the
E - stop.
– NOTE: Pushing this button will not stop the engine/motor.
2 Power On button - Press button to turn the transmitter On
3 Battery low LED - Illuminates when the transmitter battery is low
4 Function buttons:
- Button 1 or 2 - Momentary output pump forward
- Button 3 & 4 - Turns off pump reverse
- Button 5 or 6 - Latch on pump reverse and Active LED
- Button 7 - RPM decrease (optional)
- Button 8 - RPM increase (optional)
- Button 9 - Volume decrease (optional)
- Button 10 - Volume increase (optional)
5 Power Off button - Press button to turn the transmitter Off
6 Active LED/Reverse Indicator - Flashes yellow when button 5 or 6 is pressed
7 Radio receiver - Connected to receptacle on control box. Receives signal from transmitter.
– Note: For more information, please refer to the radio remote control installation/configuration
manual in the Technical Enclosures section.
A820090_03_0806D 3–37
3.16.4 Hydraulic Outriggers

Hydraulic outriggers are an option for all Thom-Katt trailer models. A double-spool manually
operated directional control valve is required to control the outrigger hydraulic cylinders:
1 2 2 6
3
2 2
4 5
A820090_03_0806D 31
Illustration 3 - 31: Hydraulic Outriggers

1 Hydraulic outrigger cylinder (RH)
2 Hydraulic fluid lines between outrigger cylinders and outrigger spool valve
3 Trailer (reference)
4 Rear jack stand weldment (RH)
5 Rear jack stand weldment (LH)
6 Hydraulic outrigger cylinder (LH)
7 Outriggers spool valve - A double-spool valve is used to control the hydraulic outriggers. One spool
is used to control the extension/retraction of the right side outrigger cylinder and the other spool
controls the left side outrigger cylinder. When lever is positioned vertically (i.e., straight up), the
hydraulic outrigger is off. Push lever towards unit to lower outrigger leg or pull lever away from unit
to raise outrigger leg.
Note
NOTICE For more detailed information on spool valves, refer to the “Spool Valves”
section.
3–38 A820090_03_0806D
3.16.5 Remixer
A remixer is an option for all Thom-Katt models. A single-spool manually operated directional
control valve is required to control the remixer pump:
5 4
4
3 5
2 6
1
1 7
A820090_03_0806D 32
Illustration 3 - 32: Remixer Assembly

1 Remixer motor - This hydraulic motor is powered by the second stage of the secondary hydraulic
pump and is controlled by the remixer spool valve.
2 Torque arm
3 Bearing
4 Hopper (reference)
5 Remixer paddles -
6 Hydraulic fluid lines going between spool valve and remixer motor
7 Remixer spool valve - This single spool directional control valve controls the remixer pump. When
lever is positioned vertically (i.e., straight up), the remixer pump is off. Push lever towards unit to
rotate remixer paddles in counterclockwise direction or pull lever away from unit to rotate remixer
paddles in clockwise direction. This spool valve has a relief valve, which can be adjusted using the
“Adjusting Remixer Relief Pressure” procedure.
Note
section.
A820090_03_0806D 3–39
3.16.6 Water Pump

A water pump is installed on all Thom-Katt Vehicle Series (VS) models, but is optional on trailer
models. A single-spool manually operated directional control valve is required to control the
water pump:
4 5
A820090_03_0806D 33
Illustration 3 - 33: Water Pump Assembly

1 Water pump - This water pump is driven by the gear motor shown above. On all truck models, this
water pump is mounted on top off a 175 gallon tank that is behind the truck cab.
2 Coupling - This coupling connects the water pump to the hydraulic gear motor.
3 Bracket - This bracket mounts the water pump assembly to the frame of the truck or trailer.
4 Hydraulic gear motor - This motor is powered by the second stage of the secondary hydraulic pump
and is controlled by the water pump spool valve.
5 Hydraulic fluid lines going between spool valve and gear motor
6 Water pump spool valve - This single spool directional control valve controls the water pump. When
lever is in a vertical position, the water pump is off. Push lever towards unit to turn water pump on.
Note
section.
3–40 A820090_03_0806D
3.16.7 Cylinder Stroke Counter

A cylinder stroke counter is an option for all Thom-Katt models:
2
A820090_03_0806D 34
Illustration 3 - 34: Cylinder Stroke Counter

1 Cylinder stroke counter - Increments by one each time the S-tube shifts.
2 Hydraulic system oil tank (reference)
When a stroke counter is installed, an electrical wire from the counter is connected to the control
cabinet and is part of the POH/stroke changeover circuitry. Each time that the S-tube shift cycles
the counter will display a numeric value.
Note
NOTICE The stroke counter only measures the S - tube shift cycles. It does not measure
pump operating hours. Engine/motor operating hours is measured by the hour
meter on the control cabinet (except for units with Deutz display).
A820090_03_0806D 3–41
3.16.8 Vibrator Kit

A vibrator kit is an option for all Thom-Katt models and is installed on the hopper grate. The
vibrator causes the hopper grate to vibrate and helps prevent bridges from forming on the hopper
grate, particularly in the case of very stiff concrete. The vibrator is electrically driven and its
connector is plugged into the round socket on the side of the electric control cabinet. The
vibrator is switched on and off at the electric control cabinet.
1
3
4
A820090_03_0806D 35
Illustration 3 - 35: Vibrator Kit
1 Hopper grate 3 Supply cable

2 Vibrator 4 Connector plug
3–42 A820090_03_0806D
3.16.9 Throttle Kit

A throttle kit is available as an option for all Thom-Katt models with diesel engines and is
installed in place of the manual engine throttle control. The harness of the throttle control is
connected to the electric control cabinet and can be operated at the control cabinet with an RPM
(+/-) toggle switch or a cable remote with RPM (+/-) toggle switch, or with a radio remote
control transmitter with RPM (+/-) pushbutton.
1
2
3
9
8
5
4 7
A820090_03_0806 36
Illustration 3 - 36: TK Throttle Kit (12V)
1 Throttle switch assembly 6 Throttle control cable

2 Throttle harness assembly 7 Bracket throttle lever
3 Bracket throttle actuator 8 Hexagon head cap screw (M6 X 12)
4 Hexagon head cap screw (5/16 - 18 X 1”) 9 Lock washer (M6)
5 Lock washer (5/16)
Note
NOTICE Do not vary the pump output by varying engine speed. Optimum engine
A820090_03_0806D 3–43
3.16.10Volume Control Kit
CAUTION
Do not vary the pump output by varying engine speed. Optimum engine
The volume control on Thom-Katts, adjusts the output discharge volume of the delivery
cylinders, which in turn is controlled by the hydraulic pump. Discharge volume may be increased
or decreased manually with the volume control knob or electrically with the electric volume
control kit.
The volume control kit is available as an option for all Thom-Katt models and is installed in place
of the manual volume control. The harness of the volume control is connected to the electric
control cabinet and can be operated at the control cabinet with a VOL (+/-) toggle switch or a
cable remote with VOL (+/-) toggle switch, or with a radio remote control transmitter with a
VOL (+/-) pushbutton.
4
1
A820090_03_0806D 37
Illustration 3 - 37: TK Volume Control Kit (12V)
1 Volume control valve 3 Minicheck test point

2 Flow control valve (12V) 4 Decal (VOL+/ - )
3–44 A820090_03_0806D
4 Travel
In this section you will find information concerning safe transport of the machine.

4.1 Towing of Trailer Models 4-2
4.2 Driving of Vehicle Series Models 4-2
4.3 Moving of Skid Models 4-3
A820090_04_0806D 4–1
Travel
4.1 Towing of Trailer Models

Prior to towing a Thom-Katt trailer model, the following safety precautions must be observed:
Note
NOTICE A Thom - Katt trailer model, although small when compared to some construction
equipment, still requires the same care and attention during transportation as
does larger heavier type equipment. It is designed to be towed at highway speeds
not to exceed 55 MPH (88 Km/H), depending on the road conditions, by a vehicle
capable of pulling the unit based on the Gross Vehicle Weight stamped on the
unit’s VIN plate.
• Check the truck and trailer tires for proper inflation pressure: Inspect tires for cuts and excessive
wear.
• Secure hitch and lock in place.
• Attach the break away cable, and safety chain to the towing truck.
• Attach trailer electrical cable to truck wiring to activate lights and electric trailer brakes when so
equipped.
• Raise and pin the outrigger legs in retracted position.
• Fully raise front jack post and store foot plate, if so equipped.
• Check tail lights, stop lights and clearance lights.
• Do not tow the unit with concrete in the hopper.
• Remove all concrete delivery line components from the pump.
4.2 Driving of Vehicle Series Models

Prior to driving a Thom-Katt Vehicle Series (VS) chassis or chassis skid-mounted model, the
following safety precautions must be observed:
• Check the tires for proper inflation pressure: Inspect tires for cuts and excessive wear.
• Check tail lights, stop lights and clearance lights.
• Do not drive the unit with concrete in the hopper.
• Remove all concrete delivery line components from the pump.
• Verify that the following items stored on the unit are properly secured:
- Delivery hoses
- Delivery pipes
- Clamps
- Tools
4.3 Moving of Skid Models

Thom-Katt skid models can be moved using a crane or a forklift capable of lifting a minimum of
7000 lbs. (3175 kg). If a crane is used, all four provided lifting eyes must be used.
4–2 A820090_04_0806D
Travel
A820090_04_0806D 1
Illustration 4 - 1: Skid frame lifting

1 Lifting eye
A820090_04_0806D 4–3
Travel
4–4 A820090_04_0806D
5 Operation
In this chapter you will find information on the operation of the machine. You will learn what
operations are required for commissioning, for setting up the machine, in pumping operations and
for cleaning.

5.1 Preliminary Information 5--2
5.2 Setup 5–2
5.3 Startup 5–6
5.4 Emergency Stop Button Locations 5--15
5.5 Maintenance During a Pour 5–17
5.6 Cleaning 5--21
5.7 Shutting Down 5--22
5.8 Pumping Concrete with the Emergency Stroke Change Kit 5--23
A820090_05_0806D 5–1
Operation
5.1 Preliminary Information

Before attempting to place material with the Thom-Katt, operators must be thoroughly trained in
its operation. Before using the Thom-Katt, complete the following steps:
• If it is a chassis-mounted or chassis skid-mounted model, perform routine truck maintenance as
outlined in your truck owner’s manual.
• For all models, completely inspect the unit for worn or damaged parts, loose bolts, missing parts,
etc.
• For all models, perform periodic maintenance on the unit, as outlined in the Maintenance section
of this manual.
WARNING
Read and comply with all safety rules, notes, and warnings contained in this
manual. This is absolutely essential to the safe, efficient operation of the unit.
5.2 Setup
5.2.1 Pre−Operation Inspection

Prior to operating the Thom-Katt pump, perform a pre-operation inspection by checking the
following items:
Note
NOTICE Performing a pre-operation inspection prevents downtime and helps maintain the
Thom-Katt in proper working condition between scheduled maintenance checks.
WARNING
Defective components, structural damage, missing parts or equipment
malfunctions, jeopardize the safety of the operator and other personnel and can
cause extensive damage to the machine. A poorly maintained machine could
become the greatest operational hazard you may encounter. It should be a
common practice that the operator perform a thorough walk-around inspection
before each day’s operation of the Thom-Katt pump.
5–2 A820090_05_0806D
Operation
WARNING
If any discrepancy is noted during the pre-inspection, perform Lock Out--Tag Out
procedure and attach a sign at the control panel stating “DO NOT OPERATE” and
repair the discrepancy before operating the Thom-Katt pump.
• Overall machine condition:

-- External structural damage
-- Wheel lug nuts (missing or loose)
-- Wiring and brake lines
-- Condition of tires (tears, cracks or cuts, inflation)
-- Missing decals, placards, warning signs
-- Missing, broken or damaged parts, bolts and nuts
-- Control panel, switches, gauges, volume control
-- Electrical system for frayed or broken wires or loose connections
• Engine
-- Fuel level
-- Oil level
-- Mounting (bolts, wiring, hoses)
-- Fuel or oil leaks
-- Belts (fan, alternator)
• Battery
-- Battery condition
-- Cables and connections (ground connection)
-- Battery hold down security
• Hydraulic System
-- Hydraulic leaks
-- Loose or damaged hoses, tubing
-- Fluid level, hydraulic tank breather cap. Refill only with an appropriate hydraulic fluid listed
in the “Recommended Lubricants” section in the Maintenance chapter.
-- Hydraulic valves and control levers
-- Cleanliness of hydraulic fluid. Non-milky, bright in color
-- Hydraulic cylinders, S--tube shift and delivery cylinders
• Hopper
-- Grate, grate safety cut-out are in place, not damaged
-- S--tube
-- Remixer paddles, drive motors
-- Outlet cleanliness
-- Lubrication
A820090_05_0806D 5–3
Operation
5.2.2 Trailer or Chassis Setup

To set up a Thom-Katt chassis, trailer, or skid-mounted unit, perform the following steps:
Note
NOTICE The Thom-Katt chassis, trailer, or skid - mounted unit should be located on level
ground as near as possible to the placement site.
1. Check the condition of the soil or flooring where the machine will be positioned. Keep
sufficient distance from excavations and slopes that could breakaway due to support loads.
Place chocks behind wheels on inclines and slopes.
2. For Thom-Katt and Katt-Kreter trailer units only, after a location has been determined level
the trailer by performing the following steps:
• Lower front leveling jack post, placing foot pad under the post. Depending on soil condition, it
might be necessary to place wooden blocking under foot pad.
• Disconnect safety chain, hitch, and electrical cable from towing vehicle.
• Lower rear outriggers and place additional blocking under pads. Pin manual legs in place.
• Level the machine using the front jack, raising or lowering as necessary.
• During the pumping operation, periodically check the levelness of the trailer unit and blocking
pads.
5.2.3 Delivery System Setup

When setting up the delivery system, observe the following recommendations:
Note
NOTICE The Thom-Katt delivery system is all the components used from the pump
discharge to the placement site. This could consist of delivery hose, steel piping,
clamps, couplers, and reducers.
• Set up the delivery line using a minimum length of rubber delivery hose. Rubber hose offers three
times the resistance to the flow of concrete as compared to steel pipe.
• Concrete will flow with less back pressure through pipe than through hose. Bends in hose or pipe
elbows will also require more pressure. The operator should take these facts into consideration
when laying out the delivery line.
• The most direct line feasible should be used from the Thom-Katt to the placement site.
• If the delivery line will cross re-bar, supports must be considered for the pipe so that it does not
contact the re-bar mat.
• The steel pipe, elbows, reducers, and hoses should be equipped with high pressure heavy duty
ends.
5–4 A820090_05_0806D
Operation
Note
NOTICE Putzmeister has available a complete stock of hoses, pipe, elbows, clamps,
couplers, and reducers to fit your needs.
CAUTION
If the delivery system has not been furnished by Putzmeister then it will be
necessary to contact the manufacturer for the maximum pressure capability of the
delivery components to be used.
• The concrete delivery system must be capable of withstanding the machine’s concrete working
pressure listed on the machine rating plate (refer to page 3–8). If a hose is used, it must have a
burst pressure that is at least 3 times the working pressure.
• It is important to size the inside diameter of the delivery system based on the size aggregate being
used. The general rule is the inside diameter should be 3 to 4 times the size of the largest
aggregate in the mix to be pumped. Here are several examples:
- 1-1/2 inch (38 mm) rock (8 to 10% maximum content by weight) requires a 5 inch (127 mm)
diameter concrete delivery system.
- 1 inch (25mm) rock (10 to 15% maximum content by weight) requires a 4 inch (100mm)
diameter concrete delivery system.
- 3/4 inch (19mm) or smaller rock (10 to 15% maximum content by weight) requires a 3 inch
(76 mm) diameter concrete delivery system.
• The hoses or pipe should be placed to the farthest point from the hopper discharge outlet first. It is
easier to remove than to add lines.
• Only couplings or clamps that are clean and seals that will retain the slurry in the delivery line
should be used.
WARNING
Dirty couplings leak, and inevitably causes blockage. Do not use any worn or
damaged hoses, pipes or couplings.
A820090_05_0806D 5–5
Operation
Note
NOTICE If your pumping job requires a vertical concrete delivery system:
– The vertical pipe line should be anchored every 10 feet (3m)
– Pumping up requires higher pumping pressure
– Pumping down can cause separation of the mixture which can cause
blockages. Maintaining back pressure in the delivery system will help to
reduce separation and blockages.
– If the machine is stopped during vertical pumping, then the back pressure
created by the weight of the material may push the “pumping” delivery cylinder
towards the water box. It is then necessary to use the “Pressure Test/Stroke
Change” switch (refer to page 3 - 12 or 3 - 16; item 5, Ill. 3 - 10 or item 9, Ill. 3 - 11 in
the General Technical Description section) to correct the cylinder at the restart
of pumping.
5.3 Start−Up
WARNING
To avoid damage to Deutz compact engines with turbochargers, when starting
engine, DO NOT run up the engine immediately to high idling speed or proceed to
full load operation from the cold state. Let engine warm up at low idling speed for
about 30 seconds. Then idle up to high idling speed and proceed to full load
operation. Cold starting with immediate run - up to high idling speed or full loading
may cause bearing damage to occur in the turbocharger.
To start-up a Thom-Katt, Katt-Kreter, or King-Katt with a diesel engine, refer to the procedures
in section 5.3.1 “Start-Up of Concrete Pump Powered by a Diesel Engine” on page 5-7.
To start-up a Vehicle Series (VS) that is powered through a PTO (Power Take-Off) unit, refer to
the procedures in section 5.3.2 “Start-Up of Concrete Pump Powered by the vehicle’s PTO.”
To start-up an electric motor powered Thom-Katt, refer to the procedures in section 5.3.3
“Start-Up of Concrete Pump Powered by an Electric Motor” on page 5-9.
5–6 A820090_05_0806D
Operation
5.3.1 Start−Up of Concrete Pump Powered by a Diesel Engine

To start a concrete pump powered by a diesel engine, perform the following steps:
1. Fill water box with water or water soluble oil.
2. At the control panel, start the pump as follows:
7
7
10
12
8 5 3 6
8 4
3
6
11 ENGINE
START
9
9 2 1 1
A820090_05_0806D 1
Illustration 5 - 1: Electric Control Cabinet
7 Pump direction toggle switch (push down for

1 Power key switch (engine start)
Forward direction)
2 Engine start pushbutton 8 Engine tachometer (digital display)
3 Alternator fault light (red) 9 Local/Remote toggle switch
4 Engine oil pressure light (red) 10 Hour meter
5 Engine fault light (red) 11 Temperature gauge
6 E - stop indicator (red) 12 EMERGENCY STOP pushbutton
• To start the engine, turn key switch (item 1, Ill. 5-1) clockwise and push the start button (item 2,
Ill. 5-1 if equipped). Allow engine to warm up several minutes if this is the first start of the day.
• Check that Emergency Stop indicator (item 6, Ill. 5-1) is not lit.
• Check that ENGINE OIL PRESSURE (item 4, Ill. 5-1), ALTERNATOR FAULT (item 3) and
ENGINE FAULT (item 5, Ill. 5-1) lights are not lit.
• Check that pump direction switch (item 7, Ill. 5-1) is in FORWARD position.
A820090_05_0806D 5–7
Operation

1 2
Engine Throttle and Volume Control

below Control Cabinet
A820090_05_0806D 2
Illustration 5 - 2: Engine Throttle and Volume Control

1 Engine throttle (with pushbutton lock)
2 Volume control
• Adjust ENGINE THROTTLE control (item 1, Ill. 5-2) counterclockwise until engine reaches
maximum speed, as read on tachometer (item 8, Ill. 5-1). Lock the throttle when maximum speed
is obtained (push-in button on throttle knob).
If using cable or radio remote control unit:
4 4
A820090_05_0806D 3
Illustration 5 - 3: Cable Remote and Radio Remote Control (Options)
1 Pump ON/OFF toggle switch 3 Pump REVERSE/FORWARD toggle switch

2 Pump ON pushbutton (radio remote only) 4 Pump FORWARD pushbutton (Button 1 or 2)
• Place Local/Remote toggle switch (item 9, Ill. 5-1) in REMOTE position.

• Place pump On/Off toggle switch (item 1, Ill. 5-3) to ON (push to right) or Push ON button (item
2, Ill. 5-3)
5–8 A820090_05_0806D
Operation
• Place pump direction toggle switch (item3, Ill. 5-3) to FORWARD position (push to left) or push
button 1 or 2 on radio remote for FORWARD pumping.
Note
NOTICE Before proceeding to cycle the pump it will be necessary to prime the pump and
delivery system. This is accomplished by pumping a coating of lubricating grout
through the S - tube and into the delivery lines. This will enable the regular
concrete mix to flow smoothly.
5.3.2 Start−Up of Concrete Pump Powered by the Vehicle’s PTO

To start a concrete pump powered by a truck engine through a power take-off (PTO) unit,
perform the following steps:
PUMP
DRIVE
A820090_05_0806D 4
Illustration 5 - 4: Power Take-Off (PTO) Switch (Located in Truck Cab)
1 Power take-off (PTO) switch - Move to the PUMP position to power the truck-mounted concrete
pump.
2 PTO light - This green indicator lamp illuminates when the PTO switch is in the PUMP position.
1. In the truck cab, start the engine and switch the PTO switch (item 1, Ill. 5-4) to pumping mode
the PTO light (item 2, Ill. 5-4) will illuminate.
A820090_05_0806D 5–9
Operation
1 2 3 4 5
7
6 7 8 9 10
8
3 4
6
9 2 1 1
12 11 13 14 15 16
A820090_05_0806D 5
1 Power indicator (green) 9 Cooler fan on indicator (green)

2 Pump running indicator (green) 10 Volume control switch
3 E - stop indicator (red) 11 Local/remote control switch (locks when in
local position
4 Hydraulic oil over - temperature indicator (red) 12 EMERGENCY SHUT-DOWN button
5 Hour meter 13 Reverse pumping on indicator (green)
6 Throttle switch 14 E-stop reset/horn switch
7 Pump on/off and reverse pumping toggle
15 Manual oil cooler fan switch
switch
8 Stroke changeover switch 16 Hydraulic oil temperature gauge
3. At the control cabinet, start the concrete pump as follows:

• Check that MAIN POWER and OIL COOLER FAN indicators (item 1 & 9, Ill. 5-5) are lit.
• Check that the pump direction switch (item 7, Ill. 5-5) is in FORWARD position.
• Adjust RPM +/- control (item 6, Ill. 5-5) until engine reaches maximum speed.
Note
5–10 A820090_05_0806D
Operation
5.3.3 Start−Up of Concrete Pump Powered by an Electric Motor

To start a concrete pump powered by an electric motor, perform the following steps:
2. Connect motor starter control box to 3-phase AC input (please refer to electrical schematic in
the Technical Data section of this manual).
2
ON
3 OFF
ON
OFF
4 RUN
START
5
6 STOP
A820090_05_0806D 6
Illustration 5 - 6: Electric Motor Start Box (460V 60Hz Y - Delta)

1 Electric motor starter control box
2 Main power circuit breaker lever - Position this lever to ON to close the main power circuit breaker
(power supply On) or to OFF to open the main power circuit breaker (power supply Off)
3 Main power ‘ON/OFF’ switch - Turns on or off 460V 60Hz input power. When switch is turned to ON
position, the red light on this switch illuminates.
4 Pump ‘RUN’ light - This green pilot light illuminates when the electric motor is running.
5 Electric motor ‘START’ pushbutton - Push this green button to start the electric motor.
6 Electric motor ‘STOP’ pushbutton - Push this red button to stop the electric motor.
DANGER
Electrocution hazard. Line voltage present with machine power off.
3. At electric motor starter control box, start the electric motor as follows:
• Close main power circuit breaker (item 2, Ill. 5-6) using lever on outside of motor starter control
box.
• Turn CONTROL PWR switch (item 3, Ill. 5-6) to ON. Verify that red light on control power
switch is illuminated.
A820090_05_0806D 5–11
Operation
• Press motor START push button (item 5, Ill. 5-6). Verify that 3-phase AC motor starts and
accelerates to rated speed. Also verify that green PUMP RUN light (item 4, Ill. 5-6)is
illuminated.
4. At the electric control cabinet, perform the following steps:
3 4
2
ENGINE
START
5 1
A820090_05_0806D 7
1 Power key switch 4 Forward/Reverse pumping toggle switch

2 Pump On/Off toggle switch 5 Local/remote control switch (locks when in
local position
3 Pump running indicator (green)
• Turn power key-switch (item 1, Ill. 5-7) to ON.

• Place pump On/Off toggle switch (item 2, Ill. 5-7) to ON position.
• Check that pump direction switch (item 4, Ill. 5-7) is in FORWARD position.
If using cable or radio remote control:
• Turn local/remote toggle switch (item 5, Ill. 5-7) to ‘Remote’ position.
• Place toggle switch (item 3, Ill. 5-3) on cable remote control to FORWARD position.
• Push FORWARD pushbutton (item 4, Ill. 5-3) on radio remote control transmitter
Note
5–12 A820090_05_0806D
Operation
5.3.4 Checking the Hopper Grate Safety Cutout Device

This machine is fitted with a hopper grate safety cutout device. A pressure roller switch is acted
on as soon as you open the hopper grate. This stops the engine/motor.
WARNING
A defective agitator safety cutout can cause you to believe that the machine is
safe, even though this is not really the case. This can lead to the remixer
continuing to run or the transfer tube switching over when the hopper grate is
open.
–You must therefore check the function of the hopper grate safety cutout device
before you start each pumping job. You must stop work if you open the hopper
grate and the electric motor or diesel engine continues to run.
A820090_05_0806D 8
Illustration 5 - 8: Checking the Hopper Grate Safety Device
1. Open the hopper grate with the concrete pump running.

2. Verify that the switching cam acts on the pressure roller switch and the diesel engine or
electric motor turns off.
Note
NOTICE You must close the hopper grate to restart the diesel engine or electric motor.
A820090_05_0806D 5–13
Operation
5.3.5 Priming of Concrete Pump and Delivery System

Prime the concrete pump and delivery system, by performing the following steps:
Note
NOTICE The grout used for priming and lubrication should consist of two parts sand and
one part cement mixed to the consistency of thick soup. This mixture will coat the
delivery line ahead of the actual concrete mix to prevent packing when the line is
being filled during pumping operations.
1. Place the necessary amount of grout in the hopper. The amount of grout needed will depend
on the length and diameter of the delivery line. Normally it will take about 5 cu. ft. (.15 m3) to
lubricate the system. Experience will eventually indicate the amount required.
2. With the necessary amount of grout in the hopper, pump it through the system by performing
the following steps:
A. Place PUMP switch (item 1, Ill. 5-9) to ON position.
2
ENGINE
START
5
6
4 3
Cable Remote with VOL Radio Remote with VOL
Engine Throttle and Volume Control
below Control Cabinet A820090_05_0806D 9
Illustration 5 - 9: Volume Control
1 Pump on/off toggle switch 4 Engine throttle (diesel engine)

2 Local/remote control toggle switch 5 Volume control toggle switch (optional)
3 Volume control knob 6 Volume increase button (optional)
5–14 A820090_05_0806D
Operation
Note
NOTICE Do not operate at full volume while priming and lubricating the system.
B. Turn VOLUME CONTROL knob (item 3, Ill. 5-9) counterclockwise to increase volume slightly
or leave at low volume.
• Ensure local/remote toggle switch (item 2, Ill. 5-9) is in remote position if you wish to use the
optional cable or radio remote control.
• On cable remote control with optional volume control toggle switch (item 5, Ill. 5-9), push toggle
switch to the right to increase volume slightly.
• On radio remote control transmitter with optional volume control buttons, push button 10 (item 6,
Ill. 5-9) to increase volume slightly.
Note
NOTICE After you have lubricated the concrete delivery system, you can proceed to pump
the concrete.
5.4 Emergency Stop Button Locations

In the event of an emergency, the diesel engine or electric motor can be shut down by pushing on
the Emergency stop button on the electric control cabinet:
2
1
ENGINE
START
A820090_05_0806D 10
Illustration 5 - 10: Emergency Stop Button on Electric Control Cabinet

1 Emergency Stop button
2 Emergency Stop indicator (red)
• At the electric control cabinet, push-in Emergency Stop button (item 1, Ill. 5-10) the red
Emergency Stop indicator will illuminate.
A820090_05_0806D 5–15
Operation
• To release the E-stop button, twist the knob clockwise

In the event of an emergency, the diesel engine or electric motor can be shut down by pushing on
the Emergency stop button on the cable remote control unit:
Note
NOTICE Pushing the Emergency Stop button on the radio remote control transmitter will
not stop the diesel engine.
A820090_05_0806D 11
Illustration 5 - 11: Emergency Stop Button Location Cable & Radio Remote Control
1 Emergency stop button - cable remote control
2 Emergency stop button - radio remote control transmitter
• At the cable remote control, push-in Emergency Stop button (item 1, Ill. 5-11).
• At the radio remote control, push-in Emergency Stop button (item 2, Ill. 5-11).
• To release the E-stop button, twist the knob clockwise.
5–16 A820090_05_0806D
Operation
5.5 Maintenance During a Pour
5.5.1 Monitoring
The displays of the monitoring instruments must be kept under observation during pumping
operations.
1 2
Y R
43 PSI (3 BAR) 50_F−300_F (10_C−150_C)

4
3
Accumulator Main System
Pressure Gauge Pressure Gauge Engine Display

A820090_05_0806D 12
(0 - 3000 PSI/0 - 207 BAR) (0 - 6000 PSI/0 - 414 Bar)
Illustration 5 - 12: Monitor Gauges During Pumping
1 Return filter condition indicator gauge 3 Hydraulic pressure guages (accumulator &
main system)
2 Hydraulic oil temperature gauge (diesel engine 4 Engine display (diesel engine models only)
models only)
" Check all displays for the monitoring instruments:

• Return filter condition indicator gauge (item 1, Ill. 5-12): Indicates the differential pressure
across the hydraulic return oil filter assembly. Normal condition is the green range (0-29 PSI)
and the filter bypasses at 43 PSI (red range). Elements should be changed if the pressure is in the
yellow range (29-43 PSI) with the hydraulic fluid at its normal operating temperature.
• Hydraulic oil temperature gauge (item 2, Ill. 5-12): the temperature of the hydraulic oil must not
exceed 194_F (90_C).
• Hydraulic pressure gauges (item 3, Ill. 5-12): Value indicated must not exceed the maximum
value specified on the machine rating plate.
A820090_05_0806D 5–17
Operation
• Diesel engine display (item 4, Ill. 5-12): Provides a digital display of engine status: engine RPM,
engine coolant temperature, operating hours, and voltage (for more information, please refer to
the Technical Enclosure “Deutz Display” included with this manual).
Note
NOTICE You must repeat these checks at regular short intervals all the time the machine is
running.
WARNING
The machine must be switched off every time a fault is indicated. All faults must
be rectified immediately, otherwise the warranty will be invalidated.
" Check the bearings and seals on the switching shaft, the pressure connection and the
agitator shaft at regular intervals.
" Lubricate the machine as required.
Note
NOTICE The bearings and seals must be replaced as soon as a cement - colored fluid and
grease mixture or slurry begins to escape.
5.5.2 Operational Tips and Precautions

Prior to and during a concrete pour, follow these tips and precautions:
• Always maintain the hopper material level to at least the height of the remixer shaft or 1/2 full
during pumping operations. If allowed to drop below this level, air will be sucked into the
delivery cylinders and the continuous smooth flow may be interrupted.
• Always have the hopper grate mounted firmly in place and never stand on the grate. Never place
any body part into the hopper while the machine is in operation.
• Prevent kinking of the end hose during concrete placement. Kinks can stop the material flow,
allowing pressure to build up in the system. When this occurs the pump must be turned OFF.
Place pump direction switch to REVERSE. Turn pump on for 2 or 3 reverse strokes in order to
relieve the pressure in the concrete delivery. Turn pump off once again and return pump direction
switch to FORWARD. Straighten out kinked hose, then resume pumping.
• During concrete placement it may be necessary to stop pumping for a period of time possibly due
to lack of concrete or other job site problems. During these periods, the concrete in the delivery
system should be moved every 10-15 minutes. This can be accomplished by pumping backwards
for 2-3 strokes then turning off pump and after another 10-15 minutes pump forward 2-3 strokes.
If the problem continues for too long, it may be necessary to clean out the delivery system and
concrete pump. Determine this from your experience with the material being pumped.
5–18 A820090_05_0806D
Operation
• If shutdown periods exceed 2-3 minutes with material in hopper, it is recommended that the
engine be shut down to prevent separation of the mixture in the hopper due to vibration from the
operating engine.
5.5.3 Avoiding Blockages

To avoid blockages, follow these tips and precautions:
• When pumping long distances or stiff mixes, you can expect a drop in volume compared to
shorter lines and wetter mixes.
• Water leaking from the coupling gaskets can cause separation of the mix in the delivery line and
subsequent blockage at that point.
• Damaged hoses with internal restrictions can cause blockages.
• When using snap joint coupling with gaskets to join hoses, wash and clean after each job. Dip
both couplings and gaskets into water prior to use for easier installation.
• A slight pulsation of the delivery hose near the pump will always be noticeable. Excessive
pulsation near the pump is normally due to higher than average line pressure caused by stiff, harsh
mixes or extremely long pumping distances. The use of hoses having larger internal diameter will
reduce the line pressure.
• The line pressure can be reduced by adding a small amount of water to the mix. The use of certain
admixtures may also help.
• Be alert to the fact that if the delivery system is blocked or kinked at start up or during the pump
operation, the pump could straighten out the kink or force out the blockage. The rapid surge of
material could cause the line to whip or move in such a manner that it may cause injury to
personnel.
• If a blockage in the hose occurs, walk along the hose until you find the point of trouble. The hose
will be soft immediately past the blockage. Elevate the hose at that point with the blockage
hanging down. Shake the hose until blockage loosens and the concrete flows freely again.
• Downhill pumping can be difficult on some jobs. When the pump is stopped, the material can
flow slowly in the delivery line causing the hose to collapse. As a result when pumping is
resumed a blockage will no doubt occur at the point of the hose collapse. This can be prevented
by kinking off the hose at the discharge while the pump is stopped. Also the use of stiffer mixes
when pumping down hill will lessen gravity flow.
• During vertical pumping up the side of a building:
- Above 40 feet (12m), use steel pipe that is securely fastened every 10 feet (3m).
- Install long radius 90_ pipe sweeps at top and bottom of steel pipe.
- Use a 25 feet (7.5m) section of hose off the pump discharge.
- Use steel pipe for the balance of the horizontal run.
A820090_05_0806D 5–19
Operation
5.5.4 Clearing a Blockage

To clear a blockage, perform the following steps:
1. When a blockage occurs in the delivery system, the pumping pressure can reach its maximum.
When the maximum pressure occurs, immediately switch off the concrete pump.
2. Change the pump direction switch to REVERSE. Turn PUMP switch to ON allowing the
pump to stroke 2 or 3 times in reverse. This will assist in relieving the pressure from the
delivery line blockage back to pump outlet.
3. Switch the pump off.
WARNING
Extreme caution must be exercised and eye protection is required when opening
clamping devices on any part of the delivery system. It is possible that pressure is
still trapped in the line. Never attempt to clear a blockage in the delivery system
using pump pressure or compressed air.
4. Warn all persons in the immediate area of this danger and clear the area. Then disconnect the
clamping device and remove the blockage.
5. After the blockage has been cleared, turn the pump on and stroke the unit at low volume until
a steady flow of material is being pumped.
6. Stop the pump and reconnect the clamping device. Turn the pump on at low volume. When
material flows steadily out the discharge, then the volume can be increased.
5–20 A820090_05_0806D
Operation
5.6 Cleaning
To clean the Thom-Katt, perform the following steps:
Note
NOTICE When the pumping operation has been concluded, it will be necessary to clean
the Thom-Katt by removing all the rest of the concrete from the hopper, swing
tube, and delivery system. Prior to performing this cleaning procedure, please
note the following:
– The flushing or cleaning operation should only be done with low RPM and low
output of the pump.
– For good wear parts and sealing conditions, the clean out of the system can be
accomplished through water pressure (i.e., pumping water).
– If the wear parts of the pump are not in the best operating condition and do not
seal precisely, the system cannot be cleaned out with water pressure. It will be
necessary to clean the unit manually. Prior to manual clean out, pump as much
concrete out of the system as possible keeping a minimum level of concrete or
water in the hopper for lubrication of the piston cups.
– Do not try to suck concrete from the pipeline with the machine. This could
damage the piston cups.
A820090_05_0806D 13
Illustration 5 - 13: No water into electric systems
Note
NOTICE In the first six weeks of operation, clean all painted surfaces with cold water only
at a maximum water pressure of 73 psi (5 bar). Do not use any aggressive
cleaning additives. Only after this length of time has the paint hardened
completely allowing you to use steam jets or similar tools.
A820090_05_0806D 5–21
Operation
1. Pump as much concrete out of the system as possible monitoring to keep a minimum level of
concrete in the hopper for lubrication of the piston cups. Then turn pump off.
2. Uncouple the delivery line at the pump outlet. If a reducer is used, disconnect the line right
after the reducer.
3. Open the hopper cleanout door and dispose of the remaining concrete.
4. Flush out with water the remainder of the concrete built up in the hopper, S-tube, material
cylinders and reducer if used. Turn pump on and cycle at lowest RPM and output.
5. Turn pump off. Place pump direction switch in REVERSE. Place water hose approximately 10
inches into pump discharge outlet and turn pump on. Water will drain into material cylinders
and as pump cycles, sand and rocks will be forced out through the open hopper clean out door.
This will take approximately 10-12 strokes.
6. Remove the hose and continue to stroke the pump to make sure all rock and sand has been
cleaned out. Turn pump off.
7. Close the hopper cleanout door. Place the cleanout sponge into the disconnected delivery line.
Reconnect the line to the hopper outlet or reducer with the sponge inserted.
8. Fill the hopper with water. Turn pump on and cycle at low RPM and output until sponge
passes through the entire delivery system.
WARNING
Attach a sponge catcher at the discharge end of the delivery system to catch the
sponge when it is discharged from the system under high pressure.
9. Turn pump off and allow water to drain from system. System can be disconnected if
appropriate.
CAUTION
Before cleaning the inside of the hopper, stop the engine, turn the ignition key off,
and wait until the accumulator gauge reads “zero.”
5–22 A820090_05_0806D
Operation
5.7 Shutting Down

If the concrete pump is put out of service or into storage, it is recommended to grease the
machine.
WARNING
To avoid damage when shutting down engine, DO NOT shut down the engine from
full load operation. Let the engine idle for about two minutes. Shutting down
engine from full load may cause a build - up of heat in the oil inside of the
turbocharger and cause failure due to blockages of the oil bores.
Note
NOTICE Greasing the concrete pump prevents corrosion and premature aging. It is
necessary if the machine:
– is not used for long periods;
– is exposed to corrosive atmospheres during storage or transportation.
" Apply grease to the concrete pump as described in the section Maintenance.
Maintenance card: Lubrication diagram
" Only close down the machine when it is disconnected from the power supply.
" Preserve the machine with a suitable agent.
A820090_05_0806D 5–23
Operation
5.8 Pumping Concrete with the Emergency Stroke Change Kit

(Diesel Engine Models Only)
All Thom-Katt models with a diesel engine come with an Emergency Stroke Change Kit. This
kit enables you to finish pumping concrete in the event of an emergency. The Emergency Stroke
Change kit consists of five wires and a toggle switch that are connected between the battery and
the hydraulic manifold assembly.
To pump concrete with the Thom-Katt Emergency Stroke Kit (P/N A052274), perform the
following steps:
WARNING
THE EMERGENCY STROKE KIT SHOULD ONLY BE USED IN AN EMERGENCY
CONDITION. THE EMERGENCY STOP (E-STOP) BUTTON DOES NOT WORK
WHEN USING THE EMERGENCY STROKE KIT.
1. Stop engine and verify that shift circuit pressure is at zero.
2. Disconnect pump harness from the following valves on the hydraulic manifold assembly:
• S-tube valve -(2 connections)
• Main control valve (2 connections)
• Accumulator dump valve (1 connection)
3. Connect Emergency Stroke Kit wiring harness to five connections disconnected in Step 2 and
battery (refer to Ill. 5-9 below):
• S-tube valve - Y1 Blue and Y2 Red
• Main control valve - Y3 Yellow and Y4 Green
• Accumulator dump valve - Y5 White
5–24 A820090_05_0806D
Operation
10 Amp Fuse
ON
Red
Black
OFF
Battery
Toggle Switch
Y3 (Yellow)
Main Y1 (Blue)
Control
Y4 (Green)
Y2 (Red)
S−Tube
Y5 (White)
Shift
Accum.
Dump
A820090_05_0806D 14
Illustration 5 - 14: Thom-Katt Emergency Stroke Kit

(Connected Between Battery and Hydraulic Manifold Assembly)
4. Start engine.
5. Use toggle switch on Emergency Stroke Kit wiring harness to shift drive cylinders and S-tube
at end of each stroke.
6. During an emergency condition or when job has been completed, stop engine by cutting off
fuel supply or disconnecting battery (i.e., removing ground wire).
A820090_05_0806D 5–25
Operation
5–26 A820090_05_0806D
6 Maintenance
Note
NOTICE The finest equipment manufactured is only as good as it’s maintenance. Costly
repair and loss of revenue can often be avoided if a good preventative
maintenance program is followed:
– The maintenance and checks noted in this section are not intended to replace
any local or regional regulations which may pertain to this type of equipment,
nor should the list and schedule be considered all inclusive. Interval times may
vary due to climate and/or conditions, depending on the location and use of the
machine.
– Always ensure that applicable safety precautions are strictly observed when
performing the maintenance inspections and checks. Make certain
adjustments, and repairs are done before operation.
– Be sure accumulator circuit is discharged before doing any work in the hopper.
– Contamination is a major cause of malfunction in hydraulic systems. Care must
be exercised to prevent dirt from entering the hydraulic system. Always cap or
plug open ports and hydraulic lines.

Lock Out - Tag Out Procedure 6-2
6.1 Maintenance Intervals 6-3
6.2 Recommended Lubricants 6-6
6.3 Inspecting the Unit 6-8
6.4 Adding Hydraulic Fluid 6-9
6.5 Lubricating the Unit 6-9
6.6 Replacing the Return Oil Filter Element 6-13
6.7 Changing the Hydraulic Fluid; Cleaning the HydraulicTank 6-14
6.8 Checking and Adjusting Hydraulic System Pressures 6-16
6.9 Adjusting Proximity Switch Settings 6-24
6.10 Replacing Proximity Switch 6-26
6.11 Performing Maintenance on the Accumulator 6-27
A820090_06_0806D 6–1
Maintenance
Lock Out Tag Out Procedure
1. Lock Out-Tag Out Procedure Where Contact With Moving Parts is Possible:
• Disengage the PTO (if engaged)
• Switch engine off and remove the key. The key must be kept by the individual performing the
work
• Put a notice on the truck near the ignition switch stating ‘Under Repair-DO NOT START’
2. Lock Out-Tag Out Procedure Where Contact With Moving Parts is Not Possible:
• The individual performing the work must engage the ‘E-stop’ on the remote control unit
• The individual performing the work must maintain complete control of the remote control unit
until the work is completed.
6–2 A820090_06_0806D
Maintenance
6.1 Maintenance Intervals

The following table shows the intervals for some of the maintenance tasks:
Every . . . Hours of
Page
Action Operation Comments
No
No.
daily 50 150 500
- Use an appropriate
Check and Hydraulic oil tank fluid level hydraulic fluid listed in the
D 6-5
Fill to Mark (with sight gauge provided) “Recommended
Lubricants” section
See above for oil type
Change Hydraulic oil tank fluid D 6-14
Tank capacity = 35 gal.
Also clean tank after any
Hydraulic oil tank D 6-14
component replacement
Clean Remove from tank, clean
Hydraulic oil tank breather D
with solvent, and blow dry
Oil cooler fins D
Drain water from hydraulic oil tank bottom after Also drain if oil appears
D
machine has set idle for 1 to 2 days milky
Use an appropriate grease
Designated grease fittings or listed in the
areas “Recommended
Refer to “Lubricating the Unit”
Lubricate Lubricants” section
Electric motor bearings procedure on page 66-99 Lubricate motor bearings
Repack with wheel bearing
Trailer wheels
grease
Every . . . Hours of
Page
Action Operation Comments
No
No.
daily 50 150 500
At normal operating
temperature, also replace
Hydraulic oil tank return filter after first 50 hours of
Replace D 6-13
element operation or if filter
indicator gauge is in red
gauge area
Refer to Deutz/Perkins engine operating manual for maintenance intervals (e.g., replacing oil/fuel/air filters, changing
oil, etc.)
A820090_06_0806D 6–3
Maintenance
Note
NOTICE Cleanliness is of the utmost importance in the maintenance of hydraulic systems.
Prevent any type of dirt from entering the system. Even small particles of dirt may
cause valves to be scored, pumps to seize and throttle and control bores to
become blocked.
– Hydraulic fluid barrels must stand for some time before the fluid is removed
from them. Never roll the barrels to where you will be drawing off the fluid.
Clean bungs and filler lids as well as the area around them before opening.
– If possible, you should use a charging set to fill up the hydraulic system. Never
leave the reservoir lid open longer than necessary.
Note
NOTICE Environmental hazard. Dispose of used filter elements in accordance with the
relevant regulations.
6–4 A820090_06_0806D
Maintenance
6.1.1 Hydraulic Oil Tank
7 1
1 4 2
3
5
Y R
G
2
6 7
6
7
Vehicle Series (VS)
3
4
High
Low
Thom−Katt,
Katt−Kreter,
5
King−Katt 4
A820090_06_0806D 1
Illustration 6 - 1: Hydraulic Oil Tank and Filters

1 Filler/breather cap
2 Tank fill strainer
3 Hydraulic oil tank
4 Hydraulic oil tank fluid level indicator and thermometer - Indicates the level, condition, and
temperature (50 - 300°F/10 - 150°C) of the fluid in the hydraulic oil tank. Do not operate pump when
oil level is below LOW level mark. The normal hydraulic fluid operating temperature range is
100 - 167_F (38 - 75_C).
5 Tank access cover
6 Return element filter assembly with 10 micron replaceable elements.
7 Return filter condition indicator gauge - Indicates the differential pressure across the hydraulic return
oil filter assembly. Normal condition is the green range (0 to 29 PSI) and the filter bypasses at 43 PSI
(red range). Elements should be changed if the pressure is in the yellow range (29 to 43 PSI) with
the hydraulic fluid at its normal operating temperature.
A820090_06_0806D 6–5
Maintenance
6.2 Recommended Lubricants

We have listed the suitable lubricants in the tables on the next page. Putzmeister accepts no
liability for the quality of the lubricants listed or for changes in quality made by the lubricant
producer without changing the grade designation.
CAUTION
Never mix hydraulic fluids of different types (i.e., do not mix biologically
degradable hydraulic fluids with mineral hydraulic fluids etc.).
CAUTION
Never use hydraulic fluids or lubricants with additives such as molybdenum. Such
additives can attack the bearings.
Note
NOTICE Please only use a hydraulic fluid complying with the requirements standard specified
in the lubricant recommendation for topping up or a full fluid change. Observe the
manufacturer’s information in doing so.
Putzmeister accepts no liability for damaged caused by mixing the oil from
different producers. When hydraulic fluids of different viscosity grades are mixed,
the new viscosity is determined by the mix ratio. Loss of quality is possible if
hydraulic fluids from different manufacturers are mixed. For this reason, you must
always consult the manufacturer before mixing fluids.
Approximately 2% of the old hydraulic fluid will remain in the lines and cylinders
after a full fluid change.
Please consult the Putzmeister After Sales Department should you discover that
the functioning of your machine is impaired with one of the lubricants or hydraulic
fluids used. We will carry out a lubricant analysis to determine the cause.
6–6 A820090_06_0806D
Maintenance
6.2.1 Hydraulic Fluids
Hydraulic Oils
To assure efficiency and long component life of your Putzmeister product, always use the correct
hydraulic oil that has been tested and proven for your product’s application. While there may be
oil suppliers that can supply a similar oil, we strongly recommend using only the hydraulic oil
that has been tested and has a proven history of success. Hydraulic components are expensive to
replace. Components that become pre-maturely worn or damaged from the using incorrect oil
are not covered by Putzmeister’s warranty. Please provide your local oil supplier with the
specific grade, i.e. (HLP VG46) as well as the required specifications (from the following charts)
that the oil must contain. Request your supplier to provide written confirmation stating that their
oil meets these requirements.
Putzmeister installs HLP VG46 mineral based oil as the standard hydraulic fluid at the factory.
This oil meets the majority of temperature requirements in the vast majority of applications. In
extremely warm or extremely cool applications, approved HLP VG68 or HLP VG46 oils may be
used. In limited applications, biodegradable oil may be used. However, caution should be used
because of the reduced acceptable operating temperature range. Contact the factory first before
switching to biodegradable oil.
Oil / Filter Change Intervals
Maintaining clean hydraulic oil is critical to the performance and life of the equipment’s
hydraulic system. As oil is initially pumped through a new system and as hydraulic components
complete their initial ‘wear-in’ cycle, the fine impurities that result are deposited in the oil and
captured by the filters. For this reason, the hydraulic filter vacuum meter should be monitored
closely, and the filters should be changed as required. The hydraulic oil should be changed every
500 hours of operation. Likewise, using the correct hydraulic oil that has been designed for this
unit will provide optimum performance and long life. Using other than the recommended
hydraulic oil may result in poor performance and premature wear or failure to components.
Please refer to the following charts when replacing the hydraulic oil. The ‘standard’ oil installed
at the factory is HLP VG46 Mineral oil. This oil has been proven to function well in a wide
variety of applications and temperature ranges. For units operating in extremely cool, or
extremely hot conditions, optional oils may be substituted during the normal oil change intervals.
A820090_06_0806D 6–7
Maintenance
Standard Hydraulic Oil (Installed at Factory)

Oil Operating Temperature Range: 14_F ( - 10_C) — 194_F (90_C)
Grade: HLP VG46 Mineral
Specifications:
Properties Putzmeister Spec
Demulsifying power < 20 min
Air release properties < 6 min
Viscosity index > 97
Pour point < 11_F ( - 12_C)
FZG gear test SKS 12
Foaming power @75_F (24_C) < 100 / 0
Foaming power @199_F (93_C) < 50 / 0
Hot Climate Applications

Specifications:
Foaming power @75_F (24_C) < 100 / 0
Foaming power @199_F (93_C) < 50 / 0
Cold Climate Applications

Specifications:
Foaming power @75_F (24_C) < 100 / 0
Foaming power @199_F (93_C) < 50 / 0
6–8 A820090_06_0806D
Maintenance
Biodegradable Oil (Contact Factory)

Oil Operating Temperature Range: 14_F (--10_C) — 146_F (80_C)
Grade: HEES 46
Specifications:
Iodine value < 10
Pour point < 6_F (--21_C)
Gear test SKS 12
Foaming power @75_F (24_C) < 100 / 0
Foaming power @199_F (93_C) < 50 / 0
6.2.2 Oils and Greases

Greasing Centralized
Engine oil1 Transmission oil2
(manual) lube system
Marking HD HYP K2K--30 K1K--30
Requirements API
API GL4 DIN 51825 DIN 51825
standard CH--4/SJ
Characteristics mineral mineral, lithium soap
SAE 90 SAE 80
Viscosity grade, SAE 15W--40 NLGI Class 2 NLGI Class 1
DIN 51512 DIN 51512
NLGI Class DIN 51511 DIN 51818 DIN 51818
Standard Winter
Part number 000173.005 000101.006 — A026511 360001.008
1Refer to engine operating manual; 2 The transmission oil for rotor pumps is listed separately.
6.3 Inspecting the Unit

To ensure a good, safe unit performance prior to start-up operations, the following items need to
be inspected daily:
Note
NOTICE By accomplishing these inspections on a daily basis, any potential malfunction
will be identified and detected before it expands into a major problem.
• Overall Machine Condition

-- Visual damage: Inspect frame and all supporting structures for weld cracks, dents or bends.
Inspect the condition of hitch, wiring, and brakes.
-- Truck springs, axles: Check for broken leaves, missing clamps, bolts, or brackets
-- Tires and wheels: Check for wear, cuts, loose or missing lug nuts, and inflation pressure
-- Lights, wiring: Check that lights operate properly and wiring is not broken or frayed
• Engine
-- Visual damage: Inspect mounting bolts, brackets
-- Oil level: Check for leaks, and proper level
A820090_06_0806D 6–9
Maintenance
- Fuel system: Inspect tank mounting, fuel level, filter condition, leaks, damaged lines
- Battery: Check battery hold down, condition and tightness of cables
- Radiator: Check for free air flow; check coolant level
• Control Panel
- Switches: Inspect for damage and function
- Electrical wiring: Inspect for fraying and cracked insulation
- Electrical connections - Check for corrosion, looseness, and good ground contact
- Gauges: Check for damage, proper operation
• Hydraulic System
- Hydraulic tank: Check fluid level and breather cap
- Hydraulic hoses: Check for leaks and damage
- Hydraulic tubing: Check for leaks and damage
- Pump, valves: Check mountings; check for leaks and damage
- Filters: Check condition of gauge; check for damage
- Oil cooler: Check for free air flow
• Pump Flat Pack
- Main cylinder: Inspect for damage, leakage of fittings, hoses, tubing
- Material cylinder: Inspect for damage, tightness of the tie rods
- Water box: Look for cracks, drain valve
- Proximity switches: Check condition
• Hopper
- Shift cylinder: Inspect connections for leaks, mounting pins/bolts
- Shift lever: Inspect for damage, connection to cylinder and S-tube. Check tightness of S-tube
nut, cotter pin
- Grating: Inspect for damage, proper position
- Grate safety cut-out: Inspect for proper operation
- S-tube: Inspect for damage of wear plate wear ring, connection to outlet
- Agitator: Inspect hydraulic motor and control for leaks and damage
6.4 Adding Hydraulic Fluid

To add hydraulic fluid to the hydraulic oil tank, perform the following steps:
Note
NOTICE The hydraulic oil tank is located just forward of the hopper (behind truck cab on
VS units) and must be kept filled to specified level at all times. Exercise extreme
care when adding fluid to the oil tank.
1. Clean area around filler opening of tank to prevent dirt and water from entering.
2. Use fresh clean hydraulic fluid. Pour fluid through the tank fill strainer.
6–10 A820090_06_0806D
Maintenance
CAUTION
Do not use a cloth for straining fluid as lint is harmful to the system.
6.5 Lubricating the Unit

To properly lubricate the Thom-Katt, perform the steps outlined in the diagram on the next page:
Note
NOTICE Refer to the “Recommended Lubricants” section on page 6 - 6 for an appropriate
grease or hydraulic fluid to use.
Note
NOTICE Rapid wear and probable component breakdown will result if the unit is operated
with inadequate lubrication. Adhere to the following lubrication guidelines:
– Do not attempt to start the equipment until lubrication points have been
checked and/or serviced.
– Pre-use lubrication does not eliminate the requirement for the next scheduled
periodic lubrication.
– Recommended lubrication intervals are based on normal use in normal
environmental conditions. The user is cautioned to adjust the lubrication
interval accordingly, to meet individual conditions and usage.
– Equipment which has been stored in/or exposed to environmental conditions of
extreme low humidity and high dust level, elevated temperatures or heavy
rainfall, may require more frequent lubrication of components than under
normal conditions.
– External non bearing surfaces shall be wiped clean of extruded or spilled
surplus grease and oil with a clean lint free cloth to prevent damaging dust and
abrasive accumulation on lubricant wet surfaces.
6.5.1 Lubrication Points for Thom−Katt, Katt−Kreter, King−Katt and VS Concrete Pumps
The lubrication points for Thom-Katt, Katt-Kreter, and King-Katt diesel engine powered trailer
and chassis skid-mounted concrete pumps are shown in Illustration 6-2. The lubrication points
for the Vehicle Series is identical except as noted. Refer to 6.2.2 ‘Oils and Greases’ for the
recommended grease to use or as specified.
A820090_06_0806D 6–11
Maintenance
Note
NOTICE Although a trailer model is shown in Illustration 6 - 2, the lubrication points on
chassis mounted models are identical except for the wheel bearings. Refer to the
chassis owner’s manual for a complete listing of the lubrication points.
1
1
5
6
4
7
3
8
4
A820090_06_0806D 2
Illustration 6- 2: Thom - Katt, Katt - Kreter, King - Katt, and VS units with Diesel Engine Lubrication Points - Lubricate
daily with an appropriate grease, except as noted:
1 2 @ remixer bearings
2 3 @ lube manifold for S-tube outlet
3 4 @ lube manifold (2 for S-tube shift cylinders; 2 for S-tube shaft bearing)
4 2 @ each S-tube shift cylinder block
5 Fill hydraulic tank to required level with an appropriate hydraulic fluid daily
6 Repack wheel bearings with wheel bearing grease quarterly (trailer models only)
7 Fill engine oil to required level with an appropriate engine oil daily
8 Lubricate main pump shaft spline with Optimoly spline grease (or equivalent)
every 500 operating hours or 6 months (whichever comes first).
6–12 A820090_06_0806D
Maintenance
6.5.2 Lubrication Points for TKS Skid−Mounted Concrete Pumps

The lubrication points for Thom-Katt TKS skid-mounted electric motor powered concrete
pumps are shown in Illustration 6-3. Refer to 6.2.2 ‘Oils and Greases’ for the recommended
grease to use or as specified.
1
1
5
4
6
3
A820090_06_0806D 3
Illustration 6- 3: TKS Skid- Mounted units with Electric Motor Lubrication Points - Lubricate daily with an appropriate
grease, except as noted:
1 2 @ remixer bearings
2 3 @ lube manifold for S-tube outlet
3 4 @ lube manifold (2 for S-tube shift cylinders; 2 for S-tube shaft bearing)
4 2 @ each S-tube shift cylinder block
5 Fill hydraulic tank to required level with an appropriate hydraulic fluid daily
A820090_06_0806D 6–13
Maintenance
6 2 grease fittings for lubricating electric motor bearings every 9 months to 1 year. Clean grease
fitting tip and apply grease gun and pump 2 - 3 strokes of ball bearing grease or polyurea grease such
as Mobil Polyrex EM or similar. For electric motors with grease drain plugs, remove the plugs and
run motor for 20 minutes to remove old grease. Replace the plugs.
CAUTION
Keep grease clean. Lubricate motors at a standstill. Do not mix petroleum grease
and silicone grease in motor bearings or damage to bearings may occur.
7 Lubricate main pump shaft spline with Optimoly spline grease (or equivalent)
every 500 operating hours or 6 months (whichever comes first).
6.6 Replacing the Return Oil Filter Element

To replace the 10 micron hydraulic return oil filter element, perform the following steps:
1 2
1
4
3
A820090_06_0806D 4
Illustration 6 - 4: Return Oil Filter Assembly
1 Hydraulic tank 3 Return oil dual - element filter assembly (All

Thom - Katt models with dual filter elements)
2 Return oil filter gauge 4 Return oil filter element (All Thom - Katt models
with single filter element)
Note
NOTICE Return filter condition indicator gauge indicates the differential pressure across
the hydraulic return oil filter assembly. Normal condition is the green range (0 to
29 PSI) and the filter bypasses at 43 PSI (red range). Elements should be changed
if the pressure is in the yellow range (29 to 43 PSI) with the hydraulic fluid at its
normal operating temperature.
1. Shut off machine. De-energize accumulator pressure.
2. Place a drain pan underneath filter housing to receive fluid drainage.
3. Remove any grime or dirt from around filter.
6–14 A820090_06_0806D
Maintenance
4. Unscrew old filter element and discard.
5. Lightly smear a small amount of oil on gasket of new filter element (Part number 311660).
6. Screw on to filter housing, hand tight plus one quarter turn.
7. Start up unit and inspect for leakage.
CAUTION
Do not attempt to wash out the old filter element. These are disposable and more
harm can be done than it is worth.
6.7 Changing the Hydraulic Fluid; Cleaning the Hydraulic Tank

To change the hydraulic fluid and clean the hydraulic tank, perform the following steps:
A820090_06_0806D 5
Illustration 6 - 5: Hydraulic Oil Tank Components
1 Filler cap 3 Tank access cover

2 Hydraulic oil tank 4 Gasket
1. Stop engine. De-energize accumulator pressure.
2. Remove filler cap (item 1, Ill. 6-4).
A820090_06_0806D 6–15
Maintenance
6.7.1 Draining the Hydraulic Oil Tank
A820090_06_0806 6
Illustration 6--6: Hydraulic Oil Tank Drain Plug

1 Hydraulic oil tank drain plug (7/8--14)
3. Place a suitably sized container under tank drain plug (item 1, Ill. 6--6) at bottom of hydraulic
oil tank (item 2, Ill. 6--5). Remove drain plug to drain tank.
4. With hydraulic tank empty, remove access cover (item 3, Ill. 6--5) located at back of tank. Take
care not to damage O--ring/gasket (item 4, Ill. 6--5) while doing this.
5. Flush inside of hydraulic tank with clean solvent and wipe clean. Remove any particles from
tank bottom.
6. Install drain plug. Re-install access cover, and gasket. Refill hydraulic tank with new “clean”
hydraulic fluid.
6–16 A820090_06_0806D
Maintenance
6.8 Checking and Adjusting Hydraulic System Pressures

This section contains procedures for checking and adjusting hydraulic system pressures. A test
gauge kit must be attached to the volume control valve test port while performing some of these
procedures:
2 1
A820090_06_0806D 7
Illustration 6 - 7: Putzmeister Test Gauge Kit

1 Test gauge #1 - This gauge consists of a small diameter hose having one end connected to a 0 - 60
BAR (0 - 882 PSI) hydraulic pressure gauge and the other end containing a female adapter.
2 Test gauge #2 - This gauge consists of same set up as test gauge #1 except a 0 - 400 BAR
(0 - 5880PSI) hydraulic pressure gauge is used.
A820090_06_0806D 8
Illustration 6 - 8: Test Port for Attaching Test Gauge #1 or #2

1 Test port - This test port is located on top of the volume control valve and is accessible from the top
of the tank enclosure
2 Volume control valve
Note
NOTICE The operational hydraulic pressures of the Thom-Katt have been checked and set
at the factory prior to shipment. Also, replacement relief valves are preset to the
correct setting prior to shipment. However, it may be necessary occasionally to
check and reset the pressures.
A820090_06_0806D 6–17
Maintenance
6.8.1 Checking Standby Pressure of The Main Hydraulic Pump

To check the standby pressure of the main hydraulic pump, perform the following steps:
1. With engine/motor shut off, remove cap from test port (on top of volume control valve) and
install Test Gauge #1.
2. Start engine and adjust THROTTLE CONTROL to maximum.
3. Adjust VOLUME CONTROL so that it is completely closed (turn clockwise).
4. Verify that pressure gauge reads 230-290 PSI (16 to 20 BAR). If indicated pressure does not
fall within specified range, then an adjustment is necessary.
WARNING
Do not activate pump switch or pressure test switch. To do so will damage the
test gauge.
6.8.2 Adjusting Standby Pressure of The Main Hydraulic Pump

To adjust the standby pressure of the main hydraulic pump, perform the following steps:
5. Leave Test Gauge #1 installed in test port. Engine can remain running.
6. Remove cap from standby pressure adjustment screw on main hydraulic pump to expose
adjustment screw. Loosen locknut.
2
3
1 2
1
A820090_06_0806D 9
Illustration 6 - 9: Location of Standby Pressure Adjustment Screw
1 Standby pressure adjustment screw 3 Regulator

2 Hydraulic pump
7. Using a #3 metric Allen wrench, turn adjustment screw (item 1, Ill. 6-9) IN to increase
pressure and turn OUT to decrease pressure. After pressure has been adjusted, tighten locknut
and replace cap.
6–18 A820090_06_0806D
Maintenance
8. Turn engine off, remove Test Gauge #1, and cap test port.
6.8.3 Checking Main System and Relief Pressure

To check main system and relief pressure, perform the following steps:
1. With engine/motor shut off, remove cap from test port (on top of volume control valve) and
install Test Gauge #2.
2
3
2
1
A820090_06_0806D 10
Illustration 6 - 10: Location of Main System Pressure Compensator Adjustment Screw
1 Pressure compensator adjustment screw 3 Regulator

2 Main hydraulic pump
2. Remove cap from pressure compensator adjustment screw on main hydraulic pump to expose
adjustment screw. Loosen locknut.
3. Start engine/motor and bring to maximum speed.
4. Turn VOLUME CONTROL open (counterclockwise) until volume is fully on.
5. Using a #3 metric Allen wrench turn pressure compensator adjustment screw (item 1, Ill.
6-10) in one to one & half turns. This will increase pressure.
6. Actuate TEST PRESSURE switch and hold. Monitor hydraulic pressure gauge. Gauge should
read the main system relief pressure setting indicated in the Hydraulic Schematic in the
Technical Data section of this manual.
7. If pressure on gauge does not read as per main system relief pressure setting indicated in table
on previous page, then an adjustment is necessary.
A820090_06_0806D 6–19
Maintenance
6.8.4 Adjusting Main System and Relief Pressure

To adjust main system and relief pressure, perform the following steps:
Hopper Side
2
4
Engine Side
A820090_06_0806D 01
Illustration 6 - 11: Location of Main System Relief Valve Adjustment Screw
1 Main system relief valve 3 Lock nut

2 Adjustment screw 4 Control block
8. Leave Test Gauge #2 installed in test port. Engine can remain running with VOLUME
CONTROL fully on.
9. Set main system relief pressure by performing the following steps:
A. Using a 9/16 in. (14 mm) wrench, loosen lock nut (item 3, Ill. 6-11) on main system relief valve
(item 1, Ill. 6-11) and adjustment screw (item 2, Ill. 6-11) located on control block (item 4, Ill.
6-11).
B. Using a #4 metric Allen wrench, turn adjust set screw IN to increase pressure and OUT to
decrease pressure.
A820090_06_0806D 12
Illustration 6 - 12: Function Switches on Control Cabinet

1 Pressure test toggle switch - Push up and hold to complete the pump stroke. At the end of the
stroke, the pump will pressure out to the maximum pressure. The maximum pressure can be read on
the main system hydraulic pressure gauge.
6–20 A820090_06_0806D
Maintenance
C. Actuate PRESSURE TEST switch (item 1, Ill. 6-12) and hold while monitoring Test Gauge #2
pressure. Adjust set screw until pressure is equal to main system relief pressure setting indicated
in Hydraulic Schematic in the Technical Data section of this manual.
D. Release PRESSURE TEST switch, and tighten relief valve adjustment screw lock nut.
10. After setting main system relief pressure, it will be necessary to set main system pressure by
performing these steps:
A. Actuate PRESSURE TEST switch and hold while monitoring Test Gauge #2 pressure. Adjust
pressure compensator adjustment screw (item 1, Ill. 6-10) on main hydraulic pump. Turn screw
out to reduce pressure until Test Gauge #2 is equal to main system pressure setting indicated.
B. Release PRESSURE TEST switch, tighten lock nut on set screw, and replace cap.
6.8.5 Checking S−Tube Shift Circuit Pressure

To check the S-tube shift circuit pressure, perform the following steps:
2 3 Engine Side
Hopper Side
A820090_06_0806D 13
Illustration 6 - 13: Location of S-tube Shift Unload and Relief Valves

(Used to Set the S-tube Shift Circuit Pressure)
1 S-tube shift unload valve (Accumulator charge 4 S-tube shift relief valve
valve)
2 Lock nut 5 Control block
3 Adjustment screw
A820090_06_0806D 6–21
Maintenance
2. Adjust VOLUME CONTROL so that it is completely closed (turn clockwise).
3. Using a 8 mm (5/16 in.) wrench, loosen lock nut (item 2, Ill. 6-13) on S-tube shift unload
valve (item 1, Ill. 6-13).
4. Using a #2.5 metric Allen wrench, turn shift unload valve adjustment screw (item 3, Ill. 6-13)
all the way in. This will increase pressure.
1 2
A820090_06_0806D 14
1 Pump On/Off toggle switch - push up to 4 Stroke change - push up temporarily to change the
turn pump On. Push down to turn pump Off drive cylinder direction and shift the S - tube (change from
pumping one cylinder to another)
5. Actuate PUMP toggle switch (item 1, Ill. 6-14) to ON and actuate STROKE CHANGE toggle
switch (item 2, Ill. 6-14).
6. Monitor accumulator pressure gauge, which indicates the shift relief valve setting.
Gauge should match the pressure setting on the Hydraulic Schematic in the Technical Data
section of this manual. If gauge reads otherwise, then an adjustment is necessary.
6–22 A820090_06_0806D
Maintenance
6.8.6 Adjusting S−Tube Shift Circuit Pressure

To adjust the S-tube shift circuit pressure, perform the following steps:
Engine Side
3
2
1 4
Hopper Side
A820011_06_0805L 15
Illustration 6 - 15: Location of S - Tube Shift Relief Valve(Used to Set the S - Tube Shift Circuit
Pressure)
1 S-tube shift relief valve (Accumulator charge 3 Adjustment screw

valve)
2 Lock nut 4 Control block
7. Using a 9/16 in. (14 mm) wrench, loosen lock nut (item 2, Ill. 6-15) on shift relief valve (item
1, Ill. 6-15) and shift relief valve adjustment screw (item 3, Ill. 6-15).
8. Using #4 metric Allen wrench, turn shift relief valve screw IN to increase pressure and OUT
to decrease pressure.
1 2
A820090_06_0806D 16
1 Pump On/Off toggle switch - push up to 4 Stroke change - push up temporarily to change the
turn pump On. Push down to turn pump Off drive cylinder direction and shift the S - tube (change from
pumping one cylinder to another)
9. Actuate PUMP toggle switch (item 1, IIl. 6-16) to ON and actuate STROKE CHANGE switch
(item 2, Ill. 6-16).
A820090_06_0806D 6–23
Maintenance
10. Monitor accumulator pressure gauge, while making adjustments so that gauge reading matches
the pressure setting on the Hydraulic Schematic in the Technical Data section of this manual.
With adjustment made and proper setting reached, tighten shift relief valve lock nut (item 2, Ill
6-15).
11. Shift unload valve (item 1, Ill. 6-13) will now require setting. Adjust shift unload valve set
screw (item 3, Ill. 6-13) out until pressure on gauge matches the pressure setting on the
Hydraulic Schematic in the Technical Data section of this manual. With adjustment made,
tighten unload valve lock nut (item 2, Ill. 6-13).
6.8.7 Adjusting Remixer Relief Pressure

To adjust the remixer relief pressure, perform the following steps:
4 5
1
5
2
3
Outrigger/Remixer Control Valve
A820090_06_0806D 17
Illustration 6 - 17: Adjusting Remixer Relief Pressure
1 Remixer 4 Manual control valve lever for the remixer motor

2 Test gauge #2 that has a range of 0 - 400 BAR 5 Remixer relief valve adjustment
(0 - 5880PSI)
3 Cap for plugging end of hose
1. Turn engine/motor off.
2. Slowly loosen hose fitting at remixer hydraulic motor (item 1, Ill. 6-17) and then disconnect
hose. Plug end of hose with cap (item 3, Ill. 6-17).
3. Install hose with pressure gauge 0-400 BAR (item 2, Ill. 6-17) on to fitting at remixer
hydraulic motor where hose was removed.
5. Actuate remixer manual control valve lever (item 4, Ill. 6-17) in appropriate direction to
pressurize remixer motor.
6–24 A820090_06_0806D
Maintenance
6. Monitor pressure gauge. Gauge should match the pressure setting on the Hydraulic Schematic
in the Technical Data section of this manual.
7. If gauge reads higher or lower, then adjust remixer relief valve (item 5, Ill. 6-17) as follows:
A. Loosen lock nut on remixer relief valve adjustment.
B. Using a #4 metric Allen wrench, turn set screw IN to increase pressure and OUT to decrease
pressure. When correct pressure is reached, tighten lock nut.
8. Turn engine/motor off.
9. Disconnect pressure gauge hose and re-install remixer motor hose.
6.9 Adjusting Proximity Switch Settings

To adjust the proximity switch settings, perform the following steps:
Note
NOTICE This procedure only applies to models that have proximity switches located in the
waterbox.
Note
NOTICE The proximity switches are used to send an electrical signal to the solenoid
valves to cycle the pump cylinders and shift the S-tube. If the proximity switches
are not properly adjusted, erratic cycling and shifting could occur. The switches
are set at the factory to provide the maximum stroke. If adjustment is to be done
to alter this setting, it is suggested that the existing position be marked or
recorded should it be necessary to revert back to the original position.
2
2.75”
A820090_06_0806D 18
Illustration 6 - 18: Location of Proximity Switches

1 Proximity switches
2 Water box
A820090_06_0806D 6–25
Maintenance
1. Measure and mark distance of 2.75 inches (57 mm) from inside face of water box on hydraulic
cylinder side to center line of proximity switch. Do this for both switches.
2. Check air gap between bottom of proximity switch and hydraulic cylinder rod adapter. Air
gap should be 5/32 inch (4 mm). Adjust air gap as follows:
" Loosen two (2) clamp mounting bolts.
" Set air gap.
" Re-tighten bolts.
Note
NOTICE The proximity switch position adjustment should only be made when the pump is
set in the FORWARD pumping direction.
3. Place water in water box.
4. Start engine/motor and bring to maximum RPM. Adjust volume control to maximum volume.
There should be no load on the unit during this procedure.
5. Place PUMP switch to ON and observe spike on main system hydraulic pressure gauge. It
should spike to 1000-1200 PSI (68-82 BAR). If pressure spike is not in this range, then
proximity switches need to be readjusted.
6. Turn off pump and engine/motor.
WARNING
Never make adjustments to switches or place your hands inside water box with
machine running.
7. Adjust each proximity switch by loosening countersunk flathead bolts and nuts and then
moving mounting bracket as indicated in table below:
If pressure spike reads . . . Then move the proximity switch mounting bracket . . .
Above 1200 PSI Away from the hydraulic drive cylinders.
Below 1000 PSI Toward the hydraulic drive cylinders.
Note
NOTICE The proximity switch mounting bracket has slots that allow the switch to be
moved forward or backward, as required. Due to variances from one machine to
another, it is difficult to specify how much movement will be required. Adjust as
needed in 1/4” increments.
8. With adjustments made, retest machine as previously noted.
6–26 A820090_06_0806D
Maintenance
6.10 Replacing Proximity Switch

To replace a proximity switch on Thom-Katt models with proximity switches located in the
hydraulic cylinders, perform the following steps:
Note
NOTICE The proximity switches are used to send an electrical signal to the solenoid
valves to cycle the pump cylinders and shift the S-tube. If the proximity switches
are not operating properly, erratic cycling and shifting could occur. You can
remove a switch from opposite side and install on side with problem. If cylinder
cycles, replace faulty switch.
Proximity Switch Location
1
Rod Side Rod Side 2 Rod Side
Rod Side Cyl. 2 Cyl. 1 Cyl. 2
Cyl. 1 (3S65.1)* (3S65.1)*
3 (3S65)*
(3S65)*
Head Side
Head Side Cyl. 2
Cyl. 1 (3S65.2)*
(3S65.2)
Cyls. Powered Cyls. Powered
on Head End on Rod End

A820090_06_0806D 19
Illustration 6 - 19: Location of Proximity Switches

*Refer to the Electrical and Hydraulic Schematic in the Technical Data section of this manual.
1 Connector plug with knurled nut
2 Magnetic switch
3 Seal ring
CAUTION
Proximity switches for changeover (S - tube shift) are marked. Pump may not
operate properly or damage may occur if the identified connector plug is
connected to the wrong proximity switch.
1. Unscrew knurled nut and remove connector plug (item 1, Ill. 6-19) from magnetic switch
(item2, Ill. 6-19).
A820090_06_0806D 6–27
Maintenance
2. Remove magnetic switch and seal ring (item 3, Ill. 6-19) from delivery cylinder.
3. Install new switch or switch from opposite side and seal ring onto delivery cylinder and
tighten.
4. Connect connector plug to magnetic switch and tighten knurled nut.
5. Test pump for proper operation.
6.11 Performing Maintenance on the Accumulator

It is recommended that the accumulator be thoroughly inspected, including a pressure test, every
5 to 10 years. To perform maintenance on the accumulator, perform the following steps:
WARNING
Adhere to the following safety regulations when performing maintenance on the
accumulator:
– The hydraulic accumulator is a pressurized vessel and only qualified technicians
should perform the necessary repairs.
– Never weld, braze, or perform any type of mechanical work on the accumulator
shell.
– Never lift the accumulator by the gas valve.
– The hydraulic oil must always be drained completely from the accumulator before
performing any work.
WARNING
Never use oxygen or air as an explosion can occur. Only use dry nitrogen or
other recommended gasses.
Note
NOTICE Pre - charge pressure should be a:
– Minimum of 25% of maximum working pressure
– Maximum of 90% of minimum working pressure
6–28 A820090_06_0806D
Maintenance
1 7
8
8
9
7 10
2
9 3
11
5
12
13
6 14
15
16
A820090_06_0806D 20
Illustration 6 - 20: Accumulator
1 Gas valve core 9 O - ring

2 Lock nut 10 Name plate
3 Shell 11 Poppet
4 Bladder 12 Seal rings
5 Anti-extrusion ring 13 Spacer ring
6 Lock nut 14 Fluid port
7 Valve seal hex cap 15 Seal ring
8 Valve protection cap 16 Vent screw
A820090_06_0806D 6–29
Maintenance
Note
NOTICE The following special tools are required to perform maintenance on the
accumulator:
– Charging and Gauging Kit (Putzmeister #AT311803)
– Gas Valve Core Tool
– Spanner Wrenches
– Bladder Pull Rod
– Sockets - 27 mm, 36 mm
– Blunt Flathead Screwdriver
– Soft Faced Hammer
– Torque Wrenches
1 5
3 8
6 9
7
A820090_06_0806D 21
Illustration 6 - 21: Charging and Gauging Kit
1 T - handle 6 Knurled cap nut

2 Manual bleed valve 7 Adapter - FPK/SB (M28 x 1.5) (7/8 - 14UNF)
3 Check valve 8 Allen wrench (6 mm)
4 Gauge (0 - 3500 psi) (0 - 250 bar) 9 Adapter - G4 (SW32)
5 Charging hose, including cap screw
connections - G1, M (SW32)
6–30 A820090_06_0806D
Maintenance
6.11.1 Checking Accumulator Pre−Charge Pressure

To check accumulator pre-charge pressure, perform the following steps:
Note
NOTICE The proper gas pre - charge pressure (1000 PSI) is set at the factory. It is
suggested that the pressure be rechecked approximately 3 - 4 months after placing
unit in service and every 12 months thereafter.
WARNING
Before checking the pre - charge pressure, be sure machine is shut down and all
hydraulic pressure and fluid in accumulator has been relieved.
1. Unscrew valve protection cap (item 8, Ill. 6-20) and valve seal hex cap (item 7, Ill. 6-20). Be
careful not to damage O-ring (item 9, 6-20) when removing cap.
2. To connect gauging unit to accumulator, perform the following steps:
Charging and
Gauging Unit
Adapter FPK/SB
N2
Hydraulic
Accumulator
A820090_06_0806 22
Illustration 6 - 22: Connecting Charging and Gauging Unit to Accumulator

• Using the 6 mm Allen wrench (item 8, Ill. 6-20) unscrew the socket head cap screw in adapter
FPK/SB (item 7, Ill. 6-20) 3 full turns counterclockwise.
A820090_06_0806D 6–31
Maintenance
NOTE: This is done to prevent gas valve damage and leakage upon installation.
• Install adapter FPK/SB onto accumulator gas valve (item 1, Ill. 6-20), hand tight.
• Close manual bleed valve on gauging unit (item 2, Ill. 6-20), hand tight.
• Connect gauging unit to adapter FPK/SB by screwing knurled cap nut (item 6, Ill. 6-20) onto the
adapter, hand tight (as shown in Ill. 6-22).
• Turn T-handle (item 1, Ill. 6-20) counterclockwise until resistance is felt.
• Install adapter onto accumulator as shown in Ill. 6-22.
3. After gauging unit has been installed, turn T-handle counterclockwise a maximum of 3 full
turns. The gauge should read the existing pre-charge pressure.
4. If gauge does not indicate 1000 PSI, perform appropriate procedure to increase or decrease
accumulator pressure:
If pressure reading is . . . Then . . . By performing this procedure . . .

< 1000 PSI Increase pressure Increasing Accumulator Pressure
> 1000 PSI Decrease pressure Decreasing Accumulator Pressure
5. If gauge indicates proper pre-charge pressure, remove charging and gauging unit by
performing the following steps:
• Turn T-handle counterclockwise until resistance is felt to close gas valve.
• Open manual bleed valve to relieve pressure in gauging unit.
• Disconnect gauging unit by unscrewing knurled cap nut from adapter.
• Re-install valve seal hex cap and tighten to 20 lb. ft. (27 Nm).
• Re-install valve protection cap, hand tight.
6.11.2 Decreasing Accumulator Pressure

To decrease pressure in accumulator, perform the following steps:
1. Install charging and gauging unit as per “Checking Accumulator Pre-Charge Pressure”
procedure on previous page.
2. Carefully open manual bleed valve, allowing gas pre-charge pressure to release slowly.
3. Monitor gauge until desired gas pressure is reached.
4. Close manual bleed valve and allow pressure to stabilize.
5. After 5-10 minutes, recheck pressure and adjust accordingly.
6–32 A820090_06_0806D
Maintenance
6. When correct pressure is reached, remove charging and gauging unit by performing the
following steps:
• Disconnect gauging unit by unscrewing cap from gas valve.
6.11.3 Increasing Accumulator Pressure
DANGER
Only use dry nitrogen gas. Never use oxygen or air because it could cause an
explosion.
WARNING
The hydraulic accumulators is a pressurized vessel and only qualified technicians
should perform the necessary repairs.
– Never weld, braze or perform any type of mechanical work on the accumulator
shell.
– Always drain the hydraulic oil completely from the accumulator before
performing any work.
CAUTION
It is recommended that the commercial nitrogen bottle be equipped with a
regulator to adjust pressure. Full pressure may damage the gauge.
To increase accumulator pressure to specified pressure (per hydraulic schematic in the Technical
Data section of this manual), perform the following steps:
A820090_06_0806D 6–33
Maintenance
Pressure
Reducer Charging and
G1 hose M hose Gauging Unit
Connection Connection
Adapter FPK/SB
Adapter G4
Charging Check
Hose Valve
N2 N2
Nitrogen Hydraulic
Bottle Accumulator
A820090_06_0806 23
Illustration 6 - 23: Connecting Charging & Gauging Kit
1. Install charging and gauging unit as shown in Ill. 6-23.

• Install adapter G4 (item 9, Ill. 6-20) onto the pressure regulator on nitrogen bottle
• Connect the G1 cap screw on the charging hose (item 5, Ill. 6-20) to adapter G4
• Connect the M cap screw on charging hose to the check valve (item 3, Ill. 6-20) of the charging
and gauging unit.
• Connect the charging and gauging unit to the adapter and acccumulator as described in 6.11.1
2. Allow 5-10 minutes for the gas temperature to stabilize.
3. Turn T-handle clockwise until gauge begins to deflect, then turn it another full turn.
4. Open shut-off valve on nitrogen bottle and slowly fill accumulator with dry nitrogen gas until
the pressure in the accumulator reaches 100 psi. Once 100 psi is reached, the charging rate can
increase. Charging too quickly may damage the accumulator.
Note
NOTICE The gauge on the gauging unit registers the line pressure and not necessarily the
accumulator pressure while charging.
5. Check accumulator pressure as follows:

• Close shut-off valve on nitrogen bottle.
• Allow gas temperature and pressure to stabilize.
• Check accumulator pressure.
6. Fill or release pressure as required until required pressure is reached.
6–34 A820090_06_0806D
Maintenance
7. When correct pressure is reached, remove nitrogen bottle and gauging unit by performing the
following steps:
• Close shut-off valve on nitrogen bottle.
• Disconnect charging hose and remove gauging unit from accumulator.
NOTE: It may be necessary to loosen the connection between the cap nut and adapter to remove
the charging and gauging unit.
• Check for leaks.
6.11.4 Replacing Accumulator Bladder

To replace the accumulator bladder, take the accumulator to a qualified hydraulic shop.
A820090_06_0806D 6–35
Maintenance
6–36 A820090_06_0806D
Maintenance Cards
In this section you will find the maintenance cards necessary for this machine. The table of
contents includes a summary of the maintenance cards in numerical order, you will find an
alphabetical summary in the Index of key words under the entry for “Maintenance cards”.
BPUS09_013_0806EN 637
638
Maintenance card
03 - 002
Page 1 of 2
6.12 Function Checks
This maintenance card describes the inspection of machine functions. The inspections are carried
out with the machine running. You will find the service intervals in the maintenance summary at
the start of this chapter.
No further maintenance cards required.
The following special tools are required:

Pressure gauge and connections for the tapping points shown in the hydraulic circuit diagram
Note
NOTICE Only qualified personnel authorized by us may carry out work on the hydraulic
system. Notify the Putzmeister After Sales department or the dealer/agent who
looks after you immediately should you find any irregularities.
" Measure the pressures generated by the pumps, using the measuring equipment speci-
fied directly on the pumps, and compare your results with the values specified in the test
reading.
" Check the proper functioning of the pressure - relief valves in the high pressure circuit
and the pressure accumulator.
WKUS03_002_0806 6–39
Maintenance Card
03 - 002
Page 2 of 2
6–40 WKUS03_002_0806
Maintenance Card
04 - 002
Page 1 of 4
6.13 Hydraulic Hose Inspection and Replacement
This maintenance card describes how to check and replace the hydraulic hoses. You will find the
maintenance intervals in the maintenance summary at the start of this chapter.
No special tools required.
Note
NOTICE Check all hoses (including hose fittings) with the machine running.
– You must replace the hoses at the slightest sign of damage or even mere
indications of threatened damage.
Leaking hoses
6.22−1
Illustration 6.22 - 1: Check hydraulic hoses
Dark and moist patches on the fitting are external signs of damage. Check:
- the hoses for kinks, cracks or a porous surface and
- whether the hoses have been laid without restrictions.
Note
NOTICE Beware of strong sunlight, the action of heat and the effects of chemicals.
WKUS04_002_0806 6–41
Maintenance Card
04 - 002
Page 2 of 4
Flared screwed joints
6.22−2
Illustration 6.22 - 2: Tighten until

there is a clearly perceptible
increase in force
" Check whether the flared screwed joints are tight.
Note
NOTICE You may only tighten leaking flared screwed joints with the permitted torque.
Tighten the joint until you clearly feel an increase in the force required if you do
not have a torque wrench available. You must replace these flared screwed joints
if leaking continues.
Flared screwed joints

External Type Max. torque External Type Max. torque
diameter Md Ft Lbs[Nm] diameter Md Ft Lbs[Nm]
6 L 15 (20) 18 L 89 (120)
8 L 30 (40) 20 S 184 (250)
L 41 (55) 25 S 295 (400)
12
S 59 (80) 30 S 369 (500)
15 L 52 (70) 38 S 590 (800)
16 S 96 (130)
6–42 WKUS04_002_0806
Maintenance Card
04 - 002
Page 3 of 4
Replacing hoses
The procedure for replacing hoses is as follows:
" Shut down the machine.
" Perform lock out - tag out procedure and secure against unauthorized starting.
" Fully dump any (residual) pressure in the hydraulic system.
WARNING
Hydraulic hoses may be mechanically pre - stressed. There is a risk of injury from
whipping hoses.
" Take care when undoing the joints.
Note
NOTICE Catch escaping fluid in a container and dispose of in an environmentally friendly
manner.
" Close the connection points with a plug immediately once you have removed the old
hoses. No dirt may enter the hydraulic circuit and the hydraulic circuit must not run
empty.
CAUTION
Hoses should not be more than six years old, including a storage time of two
years. Take note of the date of manufacture on the hoses.
" Keep the hoses free from dirt.
" Fit the hoses to be free from bends or points of abrasion.
" Bleed the hydraulic system.
" Carry out a test run and inspect all hoses again after fitting new hoses.
" Make sure hydraulic oil level is at the “Maximum” level mark on oil level indicator. Top off
if necessary.
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6.14 Delivery Piston Replacement
This maintenance card describes how to replace the delivery pistons. You will find the
maintenance intervals in the maintenance summary at the start of this chapter.
Note
NOTICE Always repair damage to the delivery pistons immediately.
Putzmeister accepts no warranty claims for damage to the machine resulting from
failure to properly observe the maintenance recommendations.
CAUTION
Follow lock out – tag out procedures and secure the working area.
You will have to start and stop the machine a number of times as you replace the delivery pistons.
The operations necessary for this are described below and must be carried out conscientiously.
Shutting down the machine
Proceed as follows to shutdown the machine:
" Set the output to zero.
" Ensure that the Reverse pumping toggle switch on the control cabinet is set to forwards
pumping.
" Stop the engine/motor.
" Check the high - pressure gauge and wait until the fluid pressure in the hydraulic system
has discharged.
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CAUTION
Make sure the accumulator pressure is discharged completely on machines with
accumulators.
CAUTION
Do not switch the pump on until you are called upon to do so. You should also
start up the pump quite slowly each time, checking that the piston travel direction
is correct.
Starting the machine - Diesel Models
" Set the throttle to one - third.
" Start the engine.
" Wait until the engine has reached a steady engine speed.
" Switch the pump on (at control cabinet or cable remote).
Starting the machine - Electric Models
" Turn main power circuit breaker lever to On position.
" Turn main power ‘On/Off’ switch to On position.
" Push the green ‘Start’ button to start the motor.
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6.14.1 Piston replacement
Pistons are replaced from the water box.
WARNING
Always shutdown the machine before you reach into the water box.
1 2 3 2 4
5
6.23.1 - 1
Illustration 6.23.1 - 1: Replacing the Piston
1 Piston rod flange 4 Delivery piston

2 Fastening bolts 5 Spacer flange
3 Securing wire
" Shutdown the machine.
" Drain the water from the water box and remove the water box cover.
" Start the machine.
" Switch the machine on and allow the hydraulic piston of the delivery piston to be re-
moved to travel slowly to its end position.
" Switch the pump off once the transfer tube has switched over.
å The spacer flange will now be visible in the water box.
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Removing a piston
1
6.23.1 - 2
Illustration 6.23.1 - 2: Piston removal

1 Fastening bolts
" Remove the wire clips from the fastening bolts and remove the bolts from the spacer
flange.
" Shift the unbolted delivery piston away from the spacer flange, which is still held fast,
with an iron bar or by striking it carefully with a hammer.
" Remove the spacer flange, and store it in such a way that it is protected against damage
until it is reinstalled.
" Switch the concrete pump on at a very low output.

å The piston rod flange approaches the delivery piston slowly.
" Bolt the delivery piston to the piston rod flange.
" Set the toggle switch on the control cabinet to reverse pumping.

å The delivery piston is withdrawn completely from the delivery cylinder.
" Undo the bolted connection on the piston rod flange and remove the old delivery piston.
" Thoroughly clean the delivery piston edge at the end of the water box.
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CAUTION
Do not use any hard objects or caustic cleaning agents to clean the delivery
cylinder. These could damage the chrome layer.
Fitting a piston
A piston is fitted in the reverse order of the operations required to remove a piston as follows.
" Grease the new delivery piston heavily with acid - free grease (e.g., Vaseline).
" Bolt the new delivery piston to the piston rod flange.

å The new delivery piston is pushed very slowly into the delivery cylinder.
" Switch the pump off before the fastening bolts for the delivery piston disappear into the
delivery cylinder.
" Undo two fastening bolts on the delivery piston.
" Set the toggle switch on the control cabinet to reverse pumping.

å The piston rod flange is drawn back.
" Switch the pump off once the spacer flange fits between the piston rod flange and the
delivery piston.
" Insert the spacer flange and fasten all the bolts.
" Tighten the bolts with the specified tightening torques and secure them with a stainless
steel wire.
Note
NOTICE Replace the second delivery piston in the same way.
" Fasten the water box cover on the water box and fill the water box with water.
" Then carry out a test run.
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650 WKUS06_023_0806
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6.15 Replacing the S - Transfer Tube
This maintenance card describes how to replace the S-transfer tube and its wear parts. You will
find the maintenance intervals in the maintenance summary at the start of this chapter.
Refer also to the maintenance cards:

07 - 015 Adjusting the S - transfer tube
10 - 007 Measuring the wall thickness

Normal tools including standard pullers for bearings, crane/lifting equipment of me-
dium loadbearing capacity and standard lifting tackle
Torques
The tightening torques can be found in the “General Tightening Torques” section at the start of
the Maintenance chapter. Torques differing from these are specified in the spare parts sheets.
CAUTION
Shut the machine down and perform lock out - tag out procedure and secure it
against unauthorized or accidental starting. Dump the accumulator pressure.
– Use only suitable lifting equipment for lifting components.
Note
NOTICE The wear parts must be replaced if visual inspection reveals wear or if there is
insufficient pressure build - up in the delivery line.
6.15.1 Dismantling the S - transfer tube bearing
The S-transfer tube is mounted in the S-transfer tube bearing in the rear wall of the hopper.
" Disconnect the pump from the delivery line.
" Open the grille on the hopper and secure it.
" Suspend the S - transfer tube from suitable lifting equipment.
" Remove the lubrication lines from the S - transfer tube bearing.
" Undo the hexagon head bolts and nuts (item 1, Ill. 6.24.1) on the pressure flange (item 2,
Ill. 6.24.1).
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" Remove the pressure flange and withdraw the pressure connection (item 3, Ill. 6.24.1)
and the S - transfer tube bearing.
3
2
6.15.1
Illustration 6.15.1: Remove pressure flange and pressure

connection
1 Hexagon head bolts / hexagon nuts 3 Pressure connection

2 Pressure flange 4 Hopper
" Check the seal rings and O - rings on the S - transfer tube bearing for wear and replace
these as required.
6.15.2 S - transfer tube bearing gasket set
6.15.2
Illustration 6.15.2: Bend the seal rings to make installation

easier
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CAUTION
Take note of the installation drawing shown in Spare Parts Sheet 7.3 - 13467,
particularly the mounting position of the grooved rings.
" Grease the new gasket set and insert.
Note
NOTICE Clean the S - transfer tube bearing before refitting and grease the seals. Check the
lubricant bores, in particular, for proper functioning. Do this by connecting the
lubrication lines and forcing the lubricant through the bores.
6.15.3 Removing the S - transfer tube shaft bearings
The switching shaft of the S-transfer tube is mounted in the switching shaft bearing (flanged
bearing) in the front wall of the hopper.
Summary
3
2
4 5
1 6
10
7 8 8
9 6.15.3−1
Illustration 6.15.3 - 1: Removal of Switching Shaft Bearings
1 Switch cylinder 7 Fastening bolt for flanged bearing (10)

2 Retaining plate 8 B fastening bolts for wear plate
3 Retaining plate fastening bolts 9 A fastening bolts for wear plate
4 Clamping bolts with nuts 10 Flanged bearing
5 Switch lever 11 (not shown) Two pulling bolts on the upper
edge of the hopper
6 Hexagon nut on the switching shaft
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" Remove any lubrication lines from the retaining plate (item 2, Ill. 6.24.3 - 1) and flanged
bearing (item 10, Ill. 6.24.3 - 1).
1
2
6.15.3−2
Illustration 6.15.3 - 2: Unbolting the retaining plate

1 Fastening bolt
2 Retaining plate
" Undo the fastening bolts (item 1, Ill. 6.24.3 - 2) on the retaining plate (item 2, Ill. 6.24.3 - 2)
and remove the retaining plate. (You will have to replace the locking plates on the fasten-
ing bolts with new ones on reassembly).
Note
NOTICE Catch the escaping hydraulic fluid in a suitable container and dispose of it in
accordance with the disposal regulations applicable for your region.
" You may disconnect the hydraulic hoses leading to the switch cylinders at the bulkhead
unions if necessary for reasons of space. Then close off the hydraulic line with plugs.
6.15.3−3
Illustration 6.15.3 - 3: Removing the switch cylinders
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Note
NOTICE You may push the switch cylinders back as illustrated, or you may screw a bolt
into the jacking bores for the ball cups and force the switch cylinders out with the
ball cups.
" Force the pistons of the switch cylinders back and remove the switch cylinders with the
hydraulic hoses.
" Undo the hexagon nuts on the switching shaft and remove the spacer ring.
6.15.3−4
Illustration 6.15.3 - 4: Loosen the clamping bolts
" Loosen the clamping bolts on the switch lever.
" Spread the switch lever apart by screwing the two jacking bolts supplied into the two
bores.
" Withdraw the switch lever from the switching shaft.
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1
2
6.15.3−5
Illustration 6.15.3 - 5: Removing flanged bearing
1 Fastening bolt 3 Flanged bearing

2 Retaining plate
" Unscrew the fastening bolt (item 1, Ill. 6.24.3 - 5)) from the flanged bearing (item 3, Ill.
6.24.3 - 5)).
" Force the flanged bearing off by screwing the two jacking bolts into the pulling bores
(item 2, Ill. 6.24.3 - 5).
" Check the seal rings and O - rings on the flanged bearing for wear and replace these as
required.
6.15.4 S - transfer tube shaft bearing gasket set
6.15.4−1
Illustration 6.15.4 - 1: Removing the retaining ring
" Remove the retaining ring.
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6.15.4−2
Illustration 6.15.4 - 2: Removing old gasket set
" Remove the old gasket set. It may be necessary to cut the seal rings to do this.
6.15.4−3
Illustration 6.15.4 - 3: Fit the new gasket set
Note
NOTICE A fitting illustration may be found in Spare Parts Sheet 7.3 - 13467.
CAUTION
Note the mounting position of the grooved ring illustrated in Spare Parts Sheet
7.3 - 13467.
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Note
NOTICE Clean the S - transfer tube shaft bearing before refitting grease the seals.
" Check the sleeve for wear and replace if necessary.
" Grease and fit the new gasket set.
" Fit the retaining ring.
6.15.5 Removing the wear plate
6.15.5−1
Illustration 6.15.5 - 1: Pushing the S - transfer tube to one side
" Push the S - transfer tube away from the wear plate.
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2
1
3
6
7
4
8
5
B B
A
6.15.5−2
Illustration 6.15.5 - 2: Removing wear plate (5 bolt style)

A - Fastening bolts (item 5)
B - Fastening bolts(item 5)
1 Wear plate 5 Socket head capscrew (A & B fastening bolts)

2 O - ring (2) 6 Wear ring (2)
3 Nylock nut (5) 7 Thrust ring (2)
4 Washer (5) 8 Spacer ring (2)
1
5
6
7
3
2
2 2
6.15.5−3
Illustration 6.15.5 - 3: Removing wear plate (2 bolt style)
1 Wear plate 5 Nylock nut (2)

2 Flat head screw (fastening bolts) 6 Wear ring (2)
3 Washer (2) 7 O - ring (2)
4 Rubber buffer(5)
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" Remove the nylock nuts and fastening bolts.
" Remove the wear plate.
6.15.6 Removing the S - transfer tube
Replace the S-transfer tube if the wall thickness has fallen below the minimum.
Note
NOTICE You may skip this procedure and continue with the “Fit the wear plate” operation
if you do not need to replace the S - transfer tube or the wear sleeve on the
S - transfer tube outlet.
6.15.6−1
Illustration 6.15.6 - 1: Removing the agitator shaft
" Remove the agitator shaft.
6.15.6−2
Illustration 6.15.6 - 2: Lifting out the S - transfer tube
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" Unbolt the scratch bar from the bottom of the S - transfer tube.
" Push the S - transfer tube forwards until the transfer tube outlet is free.
" Lift the S - transfer tube outlet opening first upwards and out.
Note
NOTICE If you wish only to replace the wear sleeve, you must also carry out the operations
on the next page and only then replace the S - transfer tube.
– If you are replacing the complete S - transfer tube, fit the new tube in the reverse
sequence to disassembly.
" Fit the new S - transfer tube.
6.15.7 Replacing the wear sleeve on the S - transfer tube
You can replace a heavily worn wear sleeve without having to replace the S-transfer tube. The
S-transfer tube must be removed to do this.
WARNING
There is a risk of burning during heating and fitting of the new wear sleeve. Use
suitable protective equipment.
CAUTION
Do not damage the transfer tube when cutting off the wear sleeve.
6.15.7
Illustration 6.15.7: Wear sleeve

1 Wear sleeve
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" Carefully cut the wear sleeve at two opposing places using an angle grinder and remove
the two parts.
Note
NOTICE The wear sleeve is chrome - plated and therefore must not be heated locally or to
too great a temperature.
" Heat the new wear sleeve uniformly to a maximum of 284_F (140_C).
" Push the heated wear sleeve over the transfer tube end and let the wear sleeve cool.
" Replace the S - transfer tube.
6.15.8 Fitting the wear plate
To make positioning of the wear plate easier during fitting, screw two short threaded rods into the
two upper threaded bores in the wear plate and insert these into the upper holes in the hopper
wall.
" Check the O - rings in the spacer ring on which the wear plate is placed.
" Clean the mounting surfaces and grease them with a multipurpose grease.
CAUTION
The wear plate lies only against the O - rings of the spacer rings. There is a small
clearance between the wear plate and the hopper wall. You should therefore only
tighten the sockethead capscrews finger - tight, as otherwise the wear plate will
break up.
6.15.8−1
Illustration 6.15.8 - 1: Fitting the wear plate
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" Install the new wear plate.
Note
NOTICE Ask our Customer Support Group for the tightening torques if a ceramic spectacle
wear plate is fitted to your machine.
Machines with 5 - bolt wear plate
1
0.02 in.
max. 0.5 mm
ÉÉÉÉÉÉ
ÉÉÉÉÉÉ
ÉÉÉÉÉÉ
ÉÉÉÉÉÉ
2
6.15.8−2
Illustration 6.15.8 - 2: Maximum distortion of the wear plate: 0.5 mm (0.02 in.)
1 Wear plate
2 Spacer ring
" Install the new wear plate and fasten it with the B
fastening bolts (outer fastening bolts; item 5, Ill. 6.24.5 - 2) and nylock nuts (item 3, Ill.
6.24.5 - 2). Tighten these finger - tight.
" Bolt down the wear plate with the A fastening bolts (top and bottom; item 5, Ill. 6.24.5 - 2)
and tighten the (top and bottom) nylock nuts with a torque wrench.
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" Then tighten the B fastening bolts (outer fastening bolts) and outer nylock nuts with the
torque wrench. The wear plate may only be distorted by a maximum of 0.5 mm (0.02 in.)
when the bolt and nuts are tightened.
Machines with 2 - bolt wear plate
1
2
4
6.15.8 - 3
Illustration 6.15.8 - 3:
1 Fastening bolt 3 Rubber buffer

2 Wear plate 4 Nylock nut
" Install the new wear plate in place and fasten it with the fastening bolts.
" Tighten the nylock nuts so that the rubber buffer is compressed by approximately 0.2 in.
(5 mm).
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6.15.9 Replacing the seal ring
Replace the seal ring in the event of heavy visible wear, if concrete is leaking or if there is
inadequate pressure build-up in the delivery line.
2
1
6.15.9
Illustration 6.15.9: Replacing the seal ring

1 Thrust ring
2 Seal ring
" Remove the old seal ring (item 2, Ill. 6.24.9) and the thrust ring (item 1, Ill. 6.24.9).
" Clean the thrust ring seat thoroughly. Dirt and concrete residue must be removed from
the seat.
" Fit a new thrust ring and a new seal ring in the S - transfer tube.
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6.15.10 Fitting the S - transfer tube bearing
3
2
6.15.10
Illustration 6.15.10: Fitting S - transfer tube bearing
1 Hexagon head bolts / hexagon nuts 3 Pressure connection

2 Pressure flange 4 Hopper
Note
NOTICE Pay attention to the location of the lubrication openings when fitting the
S - transfer tube bearing.
" Replace the S - transfer tube bearing and the pressure connection and bolt them both in
place with the pressure flange.
6.15.11 Wear sleeve and collared washer
6.15.11
Illustration 6.15.11: Locating the collared washer
" Bend the tab on the collared washer downwards.
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" Place the collared washer on the S - transfer tube shaft casing such that the tab is in-
serted in the bore and the washer is thus secured against turning.
" Insert the wear sleeve in the S - transfer tube shaft casing.
Note
NOTICE Note the position of the lubricant bores when fitting the S - transfer tube shaft
bearing.
" Grease the inside of the wear sleeve with “Anti - Seize AS 450 assembly paste” or similar
assembly grease.
" Place the complete S - transfer tube shaft bearing on the switching shaft and bolt it in
position.
Note
NOTICE The rolled pin ensures that the wear sleeve rotates with the switch lever.
The topmost tooth of the switching shaft is slightly flattened and may be used as
a marker.
6.15.12 Mounting the switch lever
6.15.12−1
Illustration 6.15.12 - 1: Inserting the rolled pin
" Insert the rolled pin into the bore in the switch lever.
" Grease the teeth on the switch lever and the switching shaft with “Anti - Seize AS 450 As-
sembly Paste” or an equivalent assembly grease.
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6.15.12−2
Illustration 6.15.12 - 2: Aligning the switch lever
" Fit the switch lever. The flattened tooth on the switching shaft must be seated in the
notch in the switch lever and the rolled pin must be located in the hole in the wear
sleeve.
" Fit the switch cylinder.
" Complete the remaining assembly operations and adjust the S - transfer tube.
Maintenance card: Adjusting the S - transfer tube.
Note
NOTICE The hydraulic system must be bled once assembly is complete if you have
removed the hydraulic hoses on the switch cylinders. Do this by starting up the
pump slowly and switching the transfer tube across slowly a few times.
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6.16 Adjusting the S - Transfer Tube
This maintenance card describes how to adjust the S-transfer tube.
CAUTION
Secure the working area. Affix warning notices to the blocked control and setting
devices.
– Keep the grille on the hopper closed during adjustment operations.
You will have to shutdown and restart the machine a number of times. The operations necessary
for this are described below and must be carried out conscientiously. As far as possible, you
should execute all machine functions from the cable remote control.
6.16.1 Shutting down the machine
Proceed as follows to shutdown the machine:
" Set the output to the minimum.
" Switch off the pump.
" Stop the engine/motor.
" Dump the pressures completely.
CAUTION
Dump the accumulator pressure completely in systems with pressure
accumulators.
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CAUTION
Do not switch the pump on until you are called upon to do so. You should also
start the pump slowly each time, checking that the piston travel direction is
correct.
6.16.2 Starting the machine
Proceed as follows to start a diesel engine model:
" Set the throttle to one - third.
" Start the engine.
" Wait until the engine has reached a steady engine speed.
Proceed as follows to start an electric motor model:
" Turn main power circuit breaker lever to On position.
" Turn main power ‘On/Off’ switch to On position.
" Push the green ‘Start’ button to start the motor.
6.16.3 Set the gap
The first part of this maintenance card describes how to adjust the gap (clearance between the
wear ring and the transfer tube).
" shutdown the machine.
Note
NOTICE The switch lever is not normally centered and vertical during disassembly as is
shown in the illustration below.
The switch cylinders do not need to be removed, as is shown in some
illustrations, for the purposes of setting the gap.
– The disassembly steps described below are unnecessary if you have already
fitted the S transfer tube following the instructions in the “Replacing the
S - transfer tube” maintenance card.
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6.16.3 - 1
Illustration 6.16.3 - 1: Unbolting the retaining plate
" Remove any lubrication lines from the retaining plate.
" Undo the fastening bolts on the retaining plate and remove the retaining plate. (You will
have to replace the locking plates on the fastening bolts with new ones on reassembly).
1 2 3
6.16.3−2
Illustration 6.16.3 - 2: Loosen hexagon nuts on switching shaft

1 Spacer ring
2 Switching shaft
3 Hexagon nut
" Undo the hexagon nuts on the switching shaft.
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6.16.3 - 3
Illustration 6.16.3 - 3: Loosen the clamping bolts
" Loosen the clamping bolts on the switch lever.
1 2 3 4 6.16.3 - 4
Illustration 6.16.3 - 4: Setting the clearance (S) between

seal ring and transfer tube
1 Transfer tube 3 Seal ring

2 Thrust ring 4 Wear plate
" Tighten the hexagon nuts on the switching shaft until the collar of the wear ring is flush
against the transfer tube.
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NOTICE The gap (clearance between seal ring and transfer tube) must be set to en-
sure that the transfer tube switches correctly.
" Undo the hexagon nuts on the switching shaft by ½ to ¾ of a turn. Line up the hexagon
nut as you do this so that the retaining plate can be fitted without problems.
å The gap “S” is now set automatically and is 0.0591 to 0.0789 inch. (1.5 to 2 mm).
NOTICE Use only new nuts for the clamping bolts.
" Remove the old nuts on the clamping bolts and fit new nuts. Tighten the clamping bolts
to 155 ft. lbs. (210 Nm).
6.16.3 - 5
Illustration 6.16.3 - 5: Tighten clamping bolts
" Further assembly is carried out in the reverse sequence to disassembly.
" Check that all covers and other safety equipment have been refitted and are fully func-
tional.
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6.16.4 Set the switching overlap
The switching overlap is set to the optimum if the wear ring is central to the relevant hole in the
wear plate for both switch positions of the S-transfer tube.
Wear plate with wear ring
1 2
6.16.4 - 1
Illustration 6.16.4 - 1: Transfer tube swing angle setting...

1 is too great
2 is too small
3 is correct
The left-hand side switching overlap is corrected by replacing the packing washer behind the ball
cup on the right-hand switch cylinder with a thicker or thinner washer respectively. The
right-hand switching overlap is corrected on the left in the same way.
1 2
3
6.16.4 - 2
Illustration 6.16.4 - 2: Replacing packing washer

1 Switch cylinder
2 Ball cup
3 Packing washer
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6.16.4 - 3
Illustration 6.16.4 - 3: Extended switch cylinder
" Allow one switch cylinder to retract fully.
6.16.4 - 4
Illustration 6.16.4 - 4: Marking the wear plate
" Mark the location of the seal ring on the wear plate with a felt - tip pen or wax crayon.
" Allow the other switch cylinder to retract.
" Determine to which side and by how far the circle you have drawn is offset against the
circle of the wear plate.
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Wear plate with sample markings
1 2
6.16.4 - 5
Illustration 6.16.4 - 5: The packing washer...

1 is too thin
2 is too thick
3 is correct
– If too thin
å The packing washer fitted must be replaced by a packing washer 0.078 Inch
(2 mm) thicker to reduce the swing angle of the transfer tube by 0.157 inch
(4 mm).
– If too thick
å The packing washer fitted must be replaced by a packing washer 0.076 Inch
(2 mm) thinner to increase the swing angle of the transfer tube by 0.157 Inch
(4 mm).
– If correct
å The packing washer does not need to be replaced.
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1 2
6.16.4 - 6
Illustration 6.16.4 - 6: Locking plate removal

1 Switch cylinder
2 Locking plate
" Remove the locking plate of the extended switch cylinder.
6.16.4 - 7
Illustration 6.16.4 - 7: Removing the switch cylinders
Note
NOTICE You may push the switch cylinders back as illustrated. You may, however, also
screw a bolt into the jacking bores for the ball cups and force the switch cylinders
out with the ball cups.
" Force the piston of the extended switch cylinder back a little and remove the switch cylin-
der with the hydraulic hoses.
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1
2
6.16.4 - 8
Illustration 6.16.4- 8: Removing ball cup and packing washer

1 Ball cup
2 Packing washer
" Remove the ball cup and packing washer.
CAUTION
No packing washers may be inserted in the switch lever, as otherwise the switch
cylinder can run over the edge of the ball cup and break it.
" Fit a thicker or thinner packing washer, as required, with the ball cup.
" Fit the switch cylinder and locking plate.
" Allow the transfer tube to switch over a few times. Stop the machine when the transfer
tube is over the side of the wear plate that has not been marked.
" Check the switching overlap of the other side of the wear plate and correct accordingly.
6.16.5 Switching overlap on fully hydraulic control (VHS)
The two switch cylinders must extend to the same extent on machines with fully hydraulic control
(VHS) and active signal tapping in the switch cylinders.
" First set one switching overlap of the wear ring and the wear plate.
" Allow the switch cylinder (1) to extend to its end position.
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6.16.5
Illustration 6.16.5: Extended switch cylinder
" Measure how far the switch cylinder has extended. (Measurement E1)
" Allow the switch cylinder (2) to extend to its end position.
" Measure how far the switch cylinder has extended. (Measurement E2)
" Compare the two measurements.
The two measurements E1 and E2 should be identical. You will have to change the packing
washers as described below if the two measurements are not equal:
" Swap the packing washer on the switch cylinder with the greater measurement for a
washer (E1 - E2):2 thinner.
" Swap the packing washer on the switch cylinder with the smaller measurement for a
washer (E1 - E2):2 thicker.
Note
NOTICE This setting must be checked after a running - in period of approximately 100
operating hours.
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6.17 Measuring the Wall Thickness (Machines with S - transfer tube)
This maintenance card describes how to measure the wall thickness of delivery lines. You will
find the maintenance intervals in the maintenance summary at the start of this chapter.

Wall thickness measuring device
Note
NOTICE Delivery lines are subject to constant wear. Measurement of the wall thickness is
particularly important before starting on large jobs.
– You will obtain reliable results for your measurements if you carry out the test
with the measuring device recommended by Putzmeister.
DANGER
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 required,
particularly if a blockage has built up.
CAUTION
Only tap the delivery line with a piece of hardwood (hammer handle). Otherwise,
dents may be created and these will lead to more rapid wear. In addition, the
hardened lining of high wear resisting pipes may flake off the inside of the pipe.
The pipe can burst at points that have suffered heavy wear.
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6.18.1
Illustration 6.18 - 1: Tapping the delivery line

with a hammer handle
Straight pipes
Uniform wear can be achieved by regularly rotating the straight delivery pipes through 120°.
The minimum wall thickness for straight pipes is shown in the graph below.
Bends
Uniform wear can be achieved by regularly rotating the bends through 180°. The wear on the
external radius of a bend is greater than that on the internal radius or on straight pipes. You
should, therefore, take special care when measuring the wall thickness of the external radius of a
bend.
The minimum wall thickness for bends is shown in the graph below.
6.18.2
Illustration 6.18 - 2: Rotate delivery pipes

and bends regularly
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6.17.1 S - transfer tube
The minimum wall thickness for the S-transfer tube depends on the maximum possible operating
pressure. Furthermore, the fact that the transfer tube is subject to greater stress at the point at
which the torque is applied (switching shaft - transfer tube) must be taken into consideration.
6.18.1
Illustration 6.18.1: X = Area of heavy loading
Operating pressure up to Guide value for wall thickness

1885.5 psi (130 bar) [mm]
Area A 0.315 - 0.394 in. [8 - 10 mm]

Area B 0.236 - 0.315 in. [6 - 8 mm]
Note
NOTICE We should draw your attention to the fact that the transfer tube is subject to
varying loading as a result of the dynamic loading during pumping. There is no
general method for calculating the minimum wall thickness for this loading, which
depends on the individual circumstances, and so the transfer tube can also burst
at an operating pressure which is assumed still to be permissible.
– You should also note that the operating pressure can rise to the maximum
pressure in the event of a blockage, and in this case the wall thickness may no
longer be adequate.
– If the operating pressure is higher than 1885.5 psi (130 bar), consult the
Putzmeister Customer Support Group what the minimum wall thickness is.
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6.17.2 Measuring
Follow the Operating Instructions supplied with the measuring device when carrying out
measurements. Do not measure the wall thickness of the delivery line at just one point, but
around the entire circumference of the delivery pipes.
The minimum wall thickness is shown in the graph below.
CAUTION
Pipes and bends must be replaced as soon as the wall thickness has declined to
the value for the minimum wall thickness.
– Putzmeister accepts no liability if the wall thickness is less than the minimum wall
thickness.
Note
NOTICE As a rule it is possible to continue pumping with an operating pressure lower than
that shown in the graph.
– We should, however, draw your attention to the fact that the delivery line is
subject to varying loading as a result of the dynamic loading during pumping.
There is no general method for calculating the minimum wall thickness for this
loading, which depends on the individual circumstances, and so the delivery line
can also burst at an operating pressure which is assumed still to be permissible.
– Furthermore, the operating pressure can rise to 1233 psi (85 bar) in the event
of blockages, meaning that the wall thickness will no longer be adequate and the
delivery line will burst.
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Graph Minimum wall thickness as a function of operating pressure

Psi (Bar)
3625 (250)
3480 (240)
3335 (230)
3191 (220)
3045 (210)
2900 (200)
2755 (190)
2610 (180)
2465 (170)
2320 (160)
2175 (150)
2030 (140)
1885 (130) 1
1740 (120)
1595 (110)
1450 (100)
1305 (90)
2
1160 (80)
1015 (70)
870 (60)
725 (50)
580 (40)
435 (30)
290 (20)
145 (10)
0
Inch 0.0 .020 .039 .059 .079 .098 .118 .138 .157 .177 .197 .217 .236 .256 .276 .295 .236 .335 .354 .374.394
(mm) (0.5) (1.0) (1.5) (2.0) (2.5) (3.0) (3.5) (4.0) (4.5) (5.0) (5.5) (6.0) (6.5) (7.0) (7.5) (8.0) (8.5) (9.0) (9.5)(10.0)
6.18.2
Illustration 6.18.2: Minimum wall thickness of delivery pipe to operating pressure

1 High pressure
2 Maximum delivery pressure
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686 WKUS10_007_0806
7 Troubleshooting Guide
The previous sections of this manual dealt with the various aspects of operation, preventative
maintenance, adjustments, and component replacement. This troubleshooting section will assist
you in recognizing and recovering from conditions that cause equipment malfunctions.
The items listed are based on logical symptoms from our experience with the Thom-Katt and
from your calls to our Technical Support Department. We need your help to continually
up-grade this section. Perhaps you and your mechanic have come across a situation not found
here and have resolved the problem. Share it with us and others like yourself. Just send it to the
Putzmeister Technical Support Department.

7.1 Engine 7–2
7.2 Hydraulic Oil Cooler 7–3
7.3 Main Hydraulic Pump 7–3
7.4 Secondary Hydraulic Pump 7–4
7.5 Control Panel Components 7–4
7.6 Hydraulic Drive Cylinders 7–5
7.7 S-Tube Shifting 7–7
7.8 Hydraulic System 7–8
7.9 Remixer 7–8
A820090_07_0806D 7–1
Troubleshooting Guide
7.1 Engine
Note
NOTICE Engine troubleshooting items noted in this section only pertain to general items
and those which may be caused by pump operation. For more serious items,
consult the Diesel Engine Manual.
Engine Cranks But Fails To Start

Possible Cause: Corrective Action:
No fuel Fill up fuel tank with a good grade of diesel fuel
Dirty fuel filter Replace fuel filter
Clogged fuel line Disconnect and air blow clean or replace fuel line
Dirty injectors Clean or replace injectors
Air leak in fuel connections Check that all fittings are tight
Engine Does Not Crank

Battery cables loose Clean and tighten cables; check grounding
Low battery Check battery output, recharge, or replace
Ignition key switch or start button switch malfunctioning Check power across contacts; replace if damaged
Check for loose connections, power across contacts;
Starter solenoid
replace if malfunctioning.
Failed starter Replace starter
Engine RPM Too Low

Throttle lever sticking Check movement; apply lubricant
Check that cable moves freely and does not bind; check connections at
Throttle control cable
throttle lever.
Readjust engine to correct idle speed (i.e., 1000 - 1200 RPM) and maximum
RPM out of adjustment
no-load speed as per nameplate on unit.
Engine Bogs Down With Full Throttle, Full Volume, and PUMP Switch ON
Horsepower limiter on main pump Contact Putzmeister Service Department. Main pump horsepower limiter
misadjusted needs to be readjusted during a full load condition.
7–2 A820090_07_0806D
Electric Motor Does Not Start

Power supply not connected Check power supply connections
Damaged power cord Check power cord for damage
Faulty switch Replace switch
Loose wire connections Check all connections
Electric Motor Hums But Does Not Start

Debris lodged in agitator or S - tube Check for debris
Low amperage:
Check amperage at power supply
Amperage at power supply insufficient
Check size of power cord
Power cord size insufficient
Check power cord for damage
Damaged power cord
7.2 Hydraulic Oil Cooler
Separate Oil Cooler Fan Fails To Operate

Loose electrical connections Check for loose connections; tighten if loose
Check relay, contacts and connections.
Relay 2K2 malfunction
Fan works off ignition switch.
Fan motor burned out Replace fan motor
Cooler Fails To Cool Hydraulic Fluid

Look for intake air restriction. Clean external dirt from oil
Blocked air flow
cooler.
Switch fan leads so that fan rotates in opposite direction
Incorrect rotation of separate oil cooler fan
(i.e., rotating fan draws air through oil cooler).
7.3 Main Hydraulic Pump
Pump Fails To Deliver Required Flow And Pressure

Adjust throttle control to full open; readjust maximum
Engine speed too low
engine no-load speed as per nameplate on unit.
Volume control set too low Adjust control to full on (open)
Check for contamination in load sensing valve or main
Load sense signal not working properly hydraulic pump standby pressure adjustment (if necessary,
remove and clean); replace any defective items.
A820090_07_0806D 7–3

Main system hydraulic pressure gauge defective Replace gauge
Check the following pressures and adjust accordingly using
the “Checking and Adjusting Hydraulic System Pressures”
procedure, in the Maintenance section:
Pressure settings incorrect
- Main hydraulic pump standby pressure
- Main hydraulic pump compensator pressure
- Main system relief pressure
High flow at case drain (i.e., defective pump) Replace main hydraulic pump
7.4 Secondary Hydraulic Pump
Pump Fails To Deliver Required Flow And Pressure

Pressure settings incorrect procedure, in the Maintenance section:
- S-tube shift circuit pressure
- S-tube shift relief pressure
Defective pump Replace secondary hydraulic pump
7.5 Control Panel Components
Hour Meter Does Not Function

Note: Hour meter operates only when pump is cycling.
Damaged wiring Check for damaged wiring; replace if damaged
Improper ground connection Check ground connection
Damaged hour meter Replace hour meter
Engine Tachometer Bounces And Will Not Read Steady

Improper ground connection Check ground connection
Alternator not functioning properly Check connections and contacts
Damaged tachometer Replace tachometer
7–4 A820090_07_0806D
Emergency Stop Switch Does Not Function

Note: Emergency stop switch stops the diesel engine
K4 relay or contacts failure Replace 1K4 relay
Emergency stop switch failure Replace E-stop switch
Alternator Fault Light (LED) Remains On

Loose alternator belt Tighten alternator belt
Failed Alternator Check alternator output; replace alternator if failed
7.6 Hydraulic Drive Cylinders
Hydraulic Cylinders Will Not Stroke With Correct Volume And Pressure
Emergency stop switch engaged Release emergency stop switch
Remove switch from opposite side and install on side with
Faulty proximity switch; no signal to change over valve
problem. If cylinder cycles, replace faulty switch.
S Check control panel for 12V DC input
S Check main cycle pilot valve solenoid connection
Insufficient electrical voltage
S Check for 12 volts to solenoid
S Check interconnecting wiring for continuity
Faulty main cycle relay 3A23 Check relay and contacts; replace relay if defective
Faulty “PUMP ON” toggle switch Replace toggle switch
A820090_07_0806D 7–5

Check coils by manually pushing on override button of the
Defective solenoid coils on main cycle pilot valve solenoid. If cylinder strokes, replace coil. If spool cannot
be shifted, remove valve and clean or replace.
S Check for 12V DC current at accumulator discharge
solenoid valve
S Check solenoid coil; replace if faulty
S Check the following pressures and adjust accordingly
using the “Checking and Adjusting Hydraulic System
Pressures” procedure:
Improper S-tube shift circuit pressure
S Remove, disassemble, and clean main cycle valve,
checking for contamination or damage. Replace damaged
spools if necessary.
S Check S-tube cylinder seals and replace if necessary.
S Check accumulator gear pump and replace if defective.
S Check hydraulic cylinders and replace if defective.
Hydraulic Cylinders Do Not Fully Extend During Cycling (i.e., Short Stroking)
S Actuate test pressure switch and hold until cylinder being
extended bottoms out; resume normal operation
S Determine if check valve on barrel side of cylinder is
Too much hydraulic oil in loop between cylinders
faulty; clean or replace check valve
S Determine if orifice on rod side is blocked; clean orifice
S Check piston seals and replace if necessary
Malfunctioning hydraulic cylinders load-sensing valve Clean or replace load-sensing valve
Hydraulic Cylinders Stroke Very Slow Even WIth High Pressure and Volume Open
Remove and clean pilot orifice. Caution: Exercise extreme
Clogged pilot orifice care when removing and installing orifice so that it will not
fall into another passage in control block.
Slurry In Water Box

Damaged delivery cylinder piston cups Replace with new piston cups
7–6 A820090_07_0806D
7.7 S−Tube Shifting
S-Tube Does Not Shift Completely To Cover Delivery Cylinder

Obstacle in hopper (e.g., wear plate binding, concrete
Check for obstacle; clear obstacle
buildup, etc.)
S-Tube Not Shifting Properly

Concrete buildup near wear ring or wear plate in hopper Remove concrete buildup
Remove switch from opposite side and install on side with
Faulty proximity switch
problem. If cylinder cycles, replace faulty switch.
Check accumulator pre-charge pressure and adjust
accordingly using the “Performing Maintenance on the
Accumulator pre-charge pressure too low
Accumulator” procedure, in the Maintenance section,
replace bladder if pressure does not hold.
S-tube shift circuit pressure too low procedure, in the Maintenance section:
Check seals by disconnecting one of the hoses from the
cylinder (i.e., with rod extended, disconnect rod side hose
S-tube shift cylinder seals leaking oil
and pressure barrel side; if oil comes out of rod side hose,
seals are leaking). If necessary, replace seals or cylinder.
S Check electrical connections to solenoid
S Check solenoid valve for 12V DC input
Malfunctioning accumulator discharge solenoid valve
S Actuate solenoid manually to shift spool
S Replace solenoid cartridge
Check coils by manually pushing on solenoid override
Defective solenoid coils on S-tube cycle valve button. If cylinder strokes, replace coil. If spool cannot be
shifted, remove valve and clean or replace.
A820090_07_0806D 7–7
Accumulator Is Not Working Properly (i.e., Pressure Builds Slow or Releases Fast)
Check accumulator pre-charge pressure and adjust
Insufficient pre-charge of bladder accordingly using the “Performing Maintenance on the
Accumulator” procedure, in the Maintenance section.
S-tube shift circuit pressure too low procedure, in the Maintenance section:
Accumulator Is Not Working Properly (i.e., Pressure Builds Slow or Releases Fast)
S Check electrical connections to solenoid
S Check solenoid coil for 12V DC input
Malfunctioning accumulator discharge solenoid valve
S Actuate solenoid manually to shift spool
S Replace solenoid cartridge
Replace bladder and pre-charge accumulator with dry
Ruptured accumulator bladder nitrogen using the “Performing Maintenance on the
Accumulator” procedure, in the Maintenance section.
7.8 Hydraulic System
Hydraulic Fluid Temperature Is Abnormally High

Malfunctioning oil cooler Refer to “Hydraulic Oil Cooler” section on page 7 – 3
Defective temperature gauge Check temperature gauge and replace if defective
Clogged oil tank breather cap Remove and clean breather cap
Drain tank; remove and clean or replace suction strainers.
Clogged suction strainers Use “Cleaning the Hydraulic Tank and Suction Strainers”
procedure in the Maintenance section.
7.9 Remixer
Remixer Will Not Rotate

Broken or missing bolt where agitator connects to drive Check agitator to drive shaft connection; replace any
shaft broken or missing bolt.
Broken key in drive shaft coupling Install new key or coupling
7–8 A820090_07_0806D

Check remixer relief valve setting and adjust accordingly
Relief valve set too low using the “Adjusting Remixer Relief Pressure” procedure in
the Maintenance section.
No oil flow to remixer control valve Check flow; if no flow, replace hydraulic pump
Malfunctioning remixer control valve Check valve operation (i.e., spool shifts easily)
Malfunctioning remixer hydraulic motor Replace hydraulic motor
A820090_07_0806D 7–9
7–10 A820090_07_0806D
Index
A 6 – 18
Cleaning, 6 – 15
Accumulator, 3 – 27 - Hydraulic oil tank, 6 – 3, 6 – 15
- Maintenance, 6 – 28, 6 – 29, 6 – 31 - Hydraulic oil tank breather, 6 – 3
Decreasing accumulator pressure, 6 – 32 - Oil cooler fins, 6 – 3
Increasing accumulator pressure, 6 – 33 - Thom -Katt unit, 5 – 21
- Troubleshooting, 7 – 8
Concrete pump start -up, 5 – 9
Adjusting
Control box, with engine display, 3 – 15
- Main system relief pressure, 6 – 20
- Proximity switch settings, 6 – 25 Control box with engine display, 3 – 15
- Remixer relief pressure, 6 – 24 Control cabinet, 3 – 12
- S -tube shift circuit pressure, 6 – 23 Control panel, Troubleshooting, 7 – 4
- Standby pressure of the main hydraulic pump, 6 – 18
Cylinder stroke counter, 3 – 41
Adjusting main system and relief pressure, 6 – 20
Adjusting remixer relief pressure, 6 – 24
Adjusting S -tube shift circuit pressure, 6 – 23 D
Adjusting standby pressure of the main hydraulic pump,
Decreasing accumulator pressure, 6 – 32
6 – 18
Delivery line, Measuring the wall thickness (Machines with
Auto-lube system, 3 – 34
S transfer tube), 6 — 81
Delivery piston, Piston replacement, 6 — 45
B Deutz engine controller and display, 3 – 14

Dismantling the S -transfer tube bearing, 6 – 51
Battery, 3 – 11, 3 – 20
Draining the hydraulic oil tank, 6 – 16
Biodegradable hydraulic oil, 6 – 9
Driving of truck models, 4 – 2
Blockages
- Clearing, 5 – 20
- Tips for avoiding, 5 – 19
E
Electric control box, 3 – 17
C Electric motor, Troubleshooting, 7 – 3
Cable remote control, electric control box, 3 – 17 Electric motor start box, 3 – 19
Cable remote control unit, 3 – 35, 3 – 36 Electrical system
- Battery, 3 – 11, 3 – 20
Cable remote TK 12V, 3 – 35
- Cable remote control, 3 – 35
Cable remote with RPM/VOL, 3 – 36 - Cable remote control with RPM/VOL, 3 – 36
Centralized lubrication system, 3 – 33 - Control panel (troubleshooting), 7 – 4
Charging and gauging kit, 6 – 30 - Electric control cabinet, 3 – 12
- Electric motor start box, 3 – 19
Checking
- Hopper grate cutout device, 3 – 31
- Accumulator pre -charge pressure, 6 – 31
- Radio remote control, 3 – 37
- S -tube shift circuit pressure, 6 – 21 Element replacement, 6 – 3, 6 – 14
- Standby Pressure of the main hydraulic pump, 6 – 18 Emergency stop button locations, 5 – 15
Checking accumulator pre -charge pressure, 6 – 31 Emergency stroke kit, 5 – 24
Checking and adjusting hydraulic system pressures, 6 – 17 Engine, Troubleshooting, 7 – 2
Checking main system and relief pressure, 6 – 19 Engine control and display (Deutz), 3 – 14
Checking S -tube shift circuit pressure, 6 – 21 Engine hand throttle, 3 – 12
Checking standby pressure of the main hydraulic pump, - VS PTO models, 3 – 21
A820090_Index_0806D i
Index
F -
-
Hydraulic drive cylinder malfunctions, 7 – 5
Hydraulic pump suction strainers, 3 – 22
Filter (hydraulic system return oil), 3 – 22, 6 – 5 - Main control block, 3 – 26
- Replacement, 6 – 14 - Main hydraulic pump, 3 – 24, 7 – 3
- Main system pressure compensator adjustment screw, 6 – 19
Fitting the S -transfer tube bearing, 6 – 66
Fitting the wear plate, 6 – 62 Adjustment, 6 – 20
Flat pack assembly, 3 – 3 Checking, 6 – 19
Foreword, 1 – 2 - Main system relief pressure adjustment screw, 6 – 20
- Oil cooler, 3 – 23, 7 – 3
Function checks, 6 – 39 - Oil tank, 6 – 3, 6 – 5, 6 – 15
- Oil tank filler cap, 6 – 5, 6 – 15
- Oil tank fluid level gauge, 6 – 5
H - Oil tank thermometer, 6 – 5
- Proximity switches (location), 6 – 27
Hopper grate safety switch, 3 – 31
- Remixer, 3 – 39
- Operational check, 5 – 13
- Remixer malfunctions, 7 – 8
Hoses - Remixer relief pressure adjustment, 6 – 24
- Leaking, 6 – 41 - Return oil filter, 3 – 22, 6 – 5
- Maintenance, 6 – 41 - Return oil filter element replacement, 6 – 3, 6 – 14
- Replacing, 6 – 43 - S -tube shift circuit pressure adjustment, 6 – 21, 6 – 23
Hydraulic circuit, 3 – 29 - S -tube shifting malfunctions, 7 – 7
- Auxiliary system, 3 – 31 - Secondary hydraulic pump, 3 – 25, 7 – 4
- Delivery cylinder pump system, 3 – 29 - Spool valves, 3 – 28
- S -tube shifting system, 3 – 30 - System pressures, 3 – 22
Hydraulic oil - Test gauge kit, 6 – 17
- Biodegradable oil, 6 – 9 - Test port, 6 – 17
- Cold climate applications, 6 – 8 Maintenance procedures
- Hot climate applications, 6 – 8 - Adding hydraulic fluid, 6 – 10
- Standard hydraulic oil, 6 – 8 - Adjusting main system and relief pressure, 6 – 20
Hydraulic oil tank, 6 – 5 - Adjusting proximity switch settings, 6 – 25
- Draining, 6 – 16 - Adjusting remixer relief pressure, 6 – 24
- Adjusting standby pressure of the main hydraulic pump, 6 – 18
Hydraulic oils, 6 – 7
- Changing the hydraulic fluid, 6 – 3, 6 – 15
Hydraulic outriggers, 3 – 38 - Checking and adjusting hydraulic system pressures, 6 – 17
Hydraulic outriggers (if equipped), 3 – 38 - Checking main system and relief pressure, 6 – 18, 6 – 19
Hydraulic pump suction strainers, cleaning, 6 – 15 - Checking S -tube shift circuit pressure, 6 – 21
- Cleaning hydraulic oil tank breather, 6 – 3
Hydraulic system, 3 – 22, 6 – 15
- Cleaning hydraulic pump suction strainers, 6 – 15
- Abnormally high fluid temperature, 7 – 8
- Cleaning oil cooler fins, 6 – 3
- Accumulator, 3 – 27
- Cleaning the hydraulic oil tank, 6 – 3, 6 – 15
- Accumulator maintenance, 6 – 29
- Decreasing accumulator pressure, 6 – 32
- Adding hydraulic fluid, 6 – 10
- Draining water from hydraulic oil tank, 6 – 3
- Adjusting standby pressure of the main hydraulic pump, 6 – 18
- Increasing accumulator pressure, 6 – 33
- Charging and gauging kit, 6 – 30
- Inspecting the unit, 6 – 9
- Checking and adjusting hydraulic system pressures, 6 – 17
- Lubricating the Thom -Katt, 6 – 3, 6 – 11
- Checking S -tube shift circuit pressure, 6 – 21
- Performing maintenance on the accumulator, 6 – 28
- Checking standby pressure of the main hydraulic pump, 6 – 18
- Replacing accumulator bladder, 6 – 35
- Draining the hydraulic oil tank, 6 – 16
- Replacing proximity switch, 6 – 27
- Filtration, 3 – 22
- Replacing return oil filter element, 6 – 3
- General, 3 – 22
- S -tube shift circuit pressure adjustment, 6 – 23
- Hydraulic circuit, 3 – 29
ii A820090_Index_0806D
Index
Hydraulic system, oil cooler fan switch, 3 – 18 Measuring, Wall thickness, 6 — 84

Measuring the wall thickness
- Machines with S transfer tube, 6 — 81
I - Measuring, 6 — 84
- S -transfer tube, 6 — 83
Icons, 1 – 3
Monitoring, 5 – 17
Increasing accumulator pressure, 6 – 33
Mounting the switch lever, 6 – 67
Moving of skid models, 4 – 2
L - Moving skid models, 4 – 2
Leaking hoses, 6 – 41
Lock Out -Tag Out Procedure, 6 – 2 O
Lubricant recommendation
Oil cooler, 3 – 23
- Hydraulic oils, 6 – 7
- Oil/Filter change intervals, 6 – 7 Oil cooler, fan switch, 3 – 18
Oil/Filter change intervals, 6 – 7 Oil filter (hydraulic system return), 6 – 5
Lubricants (recommended), 6 – 6 Oil tank (hydraulic system), 6 – 5, 6 – 15

- Filler cap, 6 – 5, 6 – 15
Lubrication points
- Fluid level gauge, 6 – 5
- Remixer, 6 – 3, 6 – 11
- maintenance, 6 – 3, 6 – 15
- S -tube, 6 – 3, 6 – 11
- Thermometer, 6 – 5
- Trailer or truck, 6 – 3, 6 – 11
Operating procedures
- Avoiding blockages, 5 – 19
M - Checking the hopper grate safety cutout device, 5 – 13

- Cleaning Thom -Katt unit, 5 – 21
Machine rating plate, 3 – 8 - Clearing a blockage, 5 – 20
- Delivery system setup, 5 – 4
Main control block, 3 – 26
- Maintenance during a pour, 5 – 17
Main hydraulic pump, 3 – 24 - Operational tips and precautions, 5 – 18
- Troubleshooting, 7 – 3 - Pre-operation inspection, 5 – 2
Maintenance - Preliminary information, 5 – 2
- During a pour, 5 – 17 - Priming of concrete pump and delivery system, 5 – 14
- Intervals, 6 – 3 - Pumping concrete with the emergency stroke kit, 5 – 24
Maintenance cards - Shutting down, 5 – 23
- Adjusting the S transfer tube, 6 — 69 - Start-up of concrete pump with diesel engine, 5 – 7
- Delivery piston replacement, 6 — 45 - Start-up of concrete pump with electric motor, 5 – 11
- Fitting the wear plate, 6 – 62 - Trailer or truck setup, 5 – 4
- Function checks, 6 – 39 Operating tips and precautions, 5 – 18
- Hoses, 6 – 41 Optional, Radio remote control, RPM/VOL, 3 – 37
- Measuring the wall thickness (Machines with S transfer tube),
Optional equipment, 3 – 34
6 — 81
- Auto -lube system, 3 – 34
- Replacing the S -transfer tube, 6 – 51
Dismantling the S -transfer tube bearing, 6 – 51 - Cable remote control unit, 3 – 35, 3 – 36
Fitting the S -transfer tube bearing, 6 – 66 - Cable remote control with RPM/VOL, 3 – 36
Mounting the switch lever, 6 – 67 - Cylinder stroke counter, 3 – 41
Removing the S -transfer tube, 6 – 60 - Hydraulic outriggers, 3 – 38
Removing the S -transfer tube shaft bearings, 6 – 53 - Radio remote control, 3 – 37
Removing the wear plate, 6 – 58 - Radio remote control unit, 3 – 37
Replacing the seal ring, 6 – 65 - Remixer, 3 – 39
Replacing the wear sleeve on the S -transfer tube, 6 – 61
- Throttle kit, 3 – 43
S -transfer tube bearing gasket set, 6 – 52, 6 – 56
Wear sleeve and collard washer, 6 – 66 - Vibrator kit, 3 – 42
A820090_Index_0806D iii
Index
- Volume control kit, 3 – 44 - Minimum wall thickness, 6 — 83

- Water pump, 3 – 40 S -transfer tube bearing gasket set, 6 – 52, 6 – 56
S -tube
P
- Removal, 6 – 60
- Replacing, 6 – 51
Performing maintenance on the accumulator, 6 – 28 - Wear parts, 6 – 51
Personnel qualifications, 2 – 2 S -tube shifting, Troubleshooting, 7 – 7
Power take -off (PTO) Safety regulations, 2 – 1, 2 – 2

- Light, 3 – 21 Secondary hydraulic pump, 3 – 25
- Switch, 3 – 21 - Troubleshooting, 7 – 4
Priming concrete pump and delivery system, 5 – 14 Setting up
Proximity switch, Location, 6 – 27 - Delivery system, 5 – 4
- Trailer or truck, 5 – 4
Pump
- Auto -lube system, 3 – 34 Shutting down, 5 – 23
- Main hydraulic, 3 – 24, 7 – 3 Spool valves, 3 – 28
- Secondary hydraulic, 3 – 25, 7 – 4 Standard hydraulic oil, 6 – 8
- Water, 3 – 40
Start-up of concrete pump with diesel engine, 5 – 7
Pumping operations, Monitoring, 5 – 17
Start-up of concrete pump with electric motor, 5 – 11
Starting up
R - Concrete pump with diesel engine, 5 – 7

- Concrete pump with electric motor, 5 – 11
Radio remote control, 3 – 37 Starting up, concrete pump, 5 – 9
Radio remote control, electric control box, 3 – 17 Storing unit, 5 – 23
Radio remote control unit, Optional, 3 – 37 Symbols, 1 – 3
- RPM/Volume, 3 – 37 Symbols for the control system, 3 – 9
Rating plate, Machine, 3 – 8 - Concrete pump, 3 – 10
Remixer, 3 – 39 - Electrical system, 3 – 9
- Troubleshooting, 7 – 8 - Engine, 3 – 9
Removing the S -transfer tube shaft bearings, 6 – 53
Removing the wear plate, 6 – 58
Repair, Lock Out -Tag Out Procedure, 6 – 2
T
Replacing Test gauge kit, 6 – 17
- Accumulator bladder, 6 – 35 Test port, 6 – 17
- Proximity switch, 6 – 27 Thom -Katt
- Return oil filter element, 6 – 14 - Auxiliary system, 3 – 31
Replacing proximity switch, 6 – 27 - Centralized lubrication system, 3 – 33
Replacing the accumulator bladder, 6 – 35 - Cleaning, 5 – 21
- Emergency stop button locations, 5 – 15
Replacing the seal ring, 6 – 65
- Inspecting the unit, 6 – 9
Replacing the wear sleeve on the S -transfer tube, 6 – 61 - Lubricants (recommended), 6 – 6
- Lubrication points, 6 – 3, 6 – 11
- Optional equipment, 3 – 34
S - Principles of operation, 3 – 2
- Setup, 5 – 2
S -transfer tube - Skid -mounted concrete pump, 3 – 5
- Adjusting, 6 — 69 - Start-up, 5 – 6
- Measuring the wall thickness, 6 — 81 - TK series trailer -mounted overview diagram, 3 – 4
iv A820090_Index_0806D
Index
- Vehicle series (VS) overview diagram, 3 – 6

- Vehicle series power take -off (VS PTO) overview diagram,
3–7
Throttle kit, 3 – 43
TK series trailer -mounted overview diagram, 3 – 4
TKS skid -mounted concrete pump, 3 – 5
Towing of trailer models, 4 – 2
Travel
- Driving of truck models, 4 – 1, 4 – 2
- Towing of trailer models, 4 – 1, 4 – 2
Troubleshooting
- Abnormally high hydraulic system fluid temperature, 7 – 8
- Accumulator, 7 – 8
- Control panel, 7 – 4
- Electric motor, 7 – 3
- Engine, 7 – 2
- Hydraulic drive cylinders, 7 – 5
- Hydraulic oil cooler, 7 – 3
- Main hydraulic pump, 7 – 3
- Remixer, 7 – 8
- S -tube shifting, 7 – 7
- Secondary hydraulic pump, 7 – 4
Truck cab controls, PTO switch and light, 3 – 21
Truck/trailer, Lubrication points, 6 – 3, 6 – 11
V
Vehicle series (VS) overview diagram, 3 – 6
Vehicle series power take -off (VS PTO) overview diagram,
3–7
Vibrator kit, 3– 42
Volume control kit, 3 – 44
W
Water pump, 3 – 40
Wear sleeve and collared washer, 6 – 66
A820090_Index_0806D v
Index
vi A820090_Index_0806D

ManualArchive 2106T2391 Operating Instructions

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ManualArchive 2106T2391 Operating Instructions

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Operating Instructions

Vehicle Series (VS)

1 Guide to the Operating Instructions . . . 1–1

1.2 Icons and Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3

2 Safety Regulations . . . . . . . . . . . . . . . . . . 2–1

2.2 Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2

3 General Technical Description . . . . . . . . 3–1

3.2 Flat Pack Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3

3.4 TKS Skid-Mounted Overview Diagram . . . . . . . . . . . . . . . . . . . . . 3–5

3.5 Vehicle Series (VS) Overview Diagram . . . . . . . . . . . . . . . . . . . . 3–6

3.6 Vehicle Series Power Take-Off (VS PTO)

3.7 Machine Rating Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–8

3.8 Symbols for the Control System . . . . . . . . . . . . . . . . . . . . . . . . . . 3–9

3.9 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–11

3.10 Electric Control Cabinet Thom - Katt, Katt - Kreter,

3.10.4 Electric Motor Start Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–19

3.11 PTO Controls (Only For VS PTO Models) . . . . . . . . . . . . . . . . . 3–21

3.12 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–22

3.13 Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–29

3.14 Hopper Grate Cutout Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–31

3.15 Centralized Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . 3–33

3.16 Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–34

4.2 Driving of Vehicle Series Models . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2

4.3 Moving of Skid Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2

5.2 Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2

5.3 Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–6

5.4 Emergency Stop Button Locations . . . . . . . . . . . . . . . . . . . . . . . 5–15

5.5 Maintenance During a Pour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–17

5.6 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–21

5.7 Shutting Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–23

5.8 Pumping Concrete with the Emergency Stroke Change Kit

6.1 Maintenance Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3

6.2 Recommended Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–6

6.3 Inspecting the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–9

6.4 Adding Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–10

6.5 Lubricating the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–11

6.6 Replacing the Return Oil Filter Element . . . . . . . . . . . . . . . . . . 6–14

6.7 Changing the Hydraulic Fluid;

6.8 Checking and Adjusting Hydraulic System Pressures . . . . . 6–17

6.9 Adjusting Proximity Switch Settings . . . . . . . . . . . . . . . . . . . . . 6–25

6.10 Replacing Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–27

6.11 Performing Maintenance on the Accumulator . . . . . . . . . . . . . 6–28

6.11.3 Increasing Accumulator Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . 6–33

6.12 Function Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–39

6.13 Hydraulic Hose Inspection and Replacement . . . . . . . . . . . . . 6–41

6.14 Delivery Piston Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 45

6.15 Replacing the S--Transfer Tube . . . . . . . . . . . . . . . . . . . . . . . . . . 6–51

6.16 Adjusting the S--Transfer Tube . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 69

6.17 Measuring the Wall Thickness

7 Troubleshooting Guide . . . . . . . . . . . . . . 7–1

7.2 Hydraulic Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–3

7.3 Main Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–3

7.4 Secondary Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–4

7.5 Control Panel Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–4

7.6 Hydraulic Drive Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–5

7.7 S-Tube Shifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–7

7.8 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–8

7.9 Remixer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–8

Putzmeister America, Inc.

or the Distributor or Dealer that looks after you.

© Copyright by Putzmeister America, Inc. 2008

1.2 Icons and Symbols

NOTICE Particular information regarding the proper use of the machine is

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