Operating Instructions

for machine operator and maintenance staff

always keep by the machine

Translation of the original Operating Instructions

Truck–mounted
concrete pump BSF 38–5.16 H NG

Machine no. 214403246

18−09−03

The paper on which this document is printed is 100% chlorine free E Putzmeister Concrete Pumps GmbH 1994
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 de Übersetzung der Originalbetriebsanleitung
bg Ïðåâîä íà îðèãèíàëíî Ðúêîâîäñòâî çà ðàáîòà
cs Pƙeklad originálního návodu k obsluze
da Oversættelse af den originale driftsvejledning
el MetÜfrash tou prwtotýpou twn odhgiþn leitourgßaj
en Translation of the original Operating Instructions
es Traducción de las instrucciones de servicio originales
et Algupärase kasutusjuhendi tõlge
fi Alkuperäisen käyttöohjeen käännös
fr Traduction des instructions de service originales
hr Prijevod izvornika naputka za uporabu
hu Eredeti üzemeltetési útmutató fordítása
it Traduzione delle istruzioni d’uso originali
lt Eksploatavimo instrukcijos originalo vertimas
lv Lietoơanas pamcbas tulkojums no oriinlvalodas
nl Vertaling van de oorspronkelijke gebruiksaanwijzing
no Oversettelse av original brukerhåndbok
pl TƂumaczenie oryginalnej instrukcji eksploatacji
pt Tradução das Instruções de funcionamento originais
ro Traducerea instrucƣiunilor de funcƣionare originale
ru Gthtdjl abhvtzzjuj herjdjlcndf gj ärcgkefnfwbb
sk Preklad originálneho návodu na obsluhu
sl Prevod izvirnih navodil za uporabo
sv Översättning av original instruktionsbok
tr Orijinal kullanűm kűlavuzunun tercümesi

BP00_030_0911EN
 Tableofcontents

Table of contents
1 Guide to the Operating Instructions
1.1 Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 — 1

1.2 Icons and symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 — 3

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

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

2.2.1 Retesting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  9
2.2.2 Inspection intervals for retesting . . . . . . . . . . . . . . . . . . . . . . . 2  10

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

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

214403175 I
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2.3.4 Extending the reach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  11

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

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

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

2.6 Operating Instructions, operating procedures and other regula-

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

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

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

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

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

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

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

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

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

2.11.1 Setup site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  27

II 214403175
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2.11.2 Supporting ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  28

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

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

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

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

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

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

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

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

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3 General technical description

3.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 1

3.2 Safety equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 3

3.3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 6

3.3.1 Electromagnetic compatibility (EMC) . . . . . . . . . . . . . . . . . . . 3  6
3.3.2 Machine rating plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  7
3.3.3 Boom rating plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  8
3.3.4 Sound pressure level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  10
3.3.5 Sound power level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  10
3.3.6 Reaches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  12

3.4 Description of the functions . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 13

3.4.1 Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  13
3.4.2 Delivery line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  13
3.4.3 Support legs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  13
3.4.4 Hydraulic control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  13
3.4.5 Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  14
3.4.6 S transfer tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  14

3.5 General conditions for using a concrete pump . . . . . . . . 3 — 15

3.5.1 Service life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  15
3.5.2 Site of use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  16
3.5.3 Height of job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  16
3.5.4 Operating temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  17

3.6 Electrical control devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 18

3.6.1 Central modular control cabinet . . . . . . . . . . . . . . . . . . . . . . . . 3  19
3.6.2 OSS equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  21
3.6.3 Ergonic Graphic Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  22
3.6.4 Ergonic Output Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  62
3.6.5 Control panel in the steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  66
3.6.6 Cable remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  68
3.6.7 Radio remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  70
3.6.8 Ergonic Graphic Display−Remote Control . . . . . . . . . . . . . . 3  75
3.6.9 Radio remote control battery charger . . . . . . . . . . . . . . . . . . . 3 111
3.6.10 EMERGENCY STOP button . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 113
3.6.11 Magnetic switches distributor casing . . . . . . . . . . . . . . . . . . . 3 116
3.6.12 Magnetic switch connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 118

IV 214403175
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3.6.13 Agitator safety cutout (RSA) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 120

3.7 Hydraulic control devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 —122

3.7.1 Support control block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 123
3.7.2 Boom control block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 126
3.7.3 Pump control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 127
3.7.4 Centralized gaugeports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 128

3.8 Other components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 —129

3.8.1 End hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 130
3.8.2 Flushing water pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 136
3.8.3 Water box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 137
3.8.4 Vibrator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 139
3.8.5 Hydraulic fluid radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 140
3.8.6 Microfilter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 143

4 Driving, towing and loading

4.1 Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 — 1
4.1.1 Hand signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  1
4.1.2 Before moving off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  2
4.1.3 During the journey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  3

4.2 Hand signals for driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 — 4

4.3 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 — 6

4.4 Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 — 10

5 Operation
5.1 Starting up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 — 1
5.1.1 Test run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  1
5.1.2 Functional fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  2
5.1.3 Engaging the transfergearbox power take−off . . . . . . . . . . . 5  3
5.1.4 Remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  8
5.1.5 Acknowledge the agitator safety cutout . . . . . . . . . . . . . . . . . 5  22

5.2 Centralized lubrication system . . . . . . . . . . . . . . . . . . . . . . . 5 — 23

5.2.1 Centralized lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . 5  24

214403175 V
 Tableofcontents

5.2.2 Filling the lubricant reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  24

5.2.3 Additional lubricationprocedure . . . . . . . . . . . . . . . . . . . . . . . 5  26

5.3 Set–up site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 — 27

5.3.1 Space requirement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  28
5.3.2 Danger zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  30
5.3.3 Lightning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  30
5.3.4 Minimum clearance from pits . . . . . . . . . . . . . . . . . . . . . . . . . . 5  31
5.3.5 Safe clearance frompits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  32
5.3.6 Supporting ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  32
5.3.7 Support area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  34

5.4 Supporting the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 — 40

5.4.1 Working area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  41
5.4.2 Remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  42
5.4.3 Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  43
5.4.4 Danger zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  45
5.4.5 Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  46
5.4.6 Spirit level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  47
5.4.7 Forward support legs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  48
5.4.8 Rear support legs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  49
5.4.9 Forward support feet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  50
5.4.10 Rear support feet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  51
5.4.11 Switching off the support function . . . . . . . . . . . . . . . . . . . . . . 5  52

5.5 Special case of “One–Side–Support“ . . . . . . . . . . . . . . . . . 5 — 53

5.5.1 Supporting the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  54
5.5.2 Restricted working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  58
5.5.3 Switching off the support function . . . . . . . . . . . . . . . . . . . . . . 5  59

5.6 Function checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 — 60

5.6.1 Pump functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  60
5.6.2 Filter functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  62
5.6.3 EMERGENCY STOP function . . . . . . . . . . . . . . . . . . . . . . . . . . 5  64
5.6.4 Function check on the boom control block . . . . . . . . . . . . . . 5  66
5.6.5 Function check of the agitator safety cutout . . . . . . . . . . . . . 5  67

5.7 Boom movements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 — 69

5.7.1 Restrictions on use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  70
5.7.2 Danger zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  71

VI 214403175
 Tableofcontents

5.7.3 Spontaneous retraction of the boom cylinders and support cylinders

5 75
5.7.4 Uncontrolled boom movements . . . . . . . . . . . . . . . . . . . . . . . . 5  77

5.8 Hand signals for boom and pumping operations . . . . . . 5 — 79

5.9 Unfolding the 5 RZ boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 — 86

5.9.1 Unfolding sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  87
5.9.2 Impermissible working range . . . . . . . . . . . . . . . . . . . . . . . . . . 5  93

5.10 Unfolding the boom when using One–Side–Support . . . 5 — 94

5.11 Filling and draining the water box . . . . . . . . . . . . . . . . . . . . 5 —100

5.12 Pumping operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 —103

5.12.1 Dangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 103
5.12.2 Notes on correct pumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 107
5.12.3 Starting pumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 110
5.12.4 Pumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 111
5.12.5 Possible faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 113
5.12.6 Special cases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 117

5.13 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 —119

5.13.1 Delivery line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 127
5.13.2 Hopper, delivery cylinder and Stransfer tube . . . . . . . . . . . . 5 134
5.13.3 Truck superstructure and postwashing operations . . . . . . . 5 143

5.14 Driving position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 —145

5.14.1 Folding sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 146
5.14.2 Retracting thesupports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 149
5.14.3 Remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 150
5.14.4 Disengaging the transfer gearbox power take−off . . . . . . . . 5 152

5.15 Driving position when using One-Side-Support . . . . . . . . 5 —156

5.15.1 Retracting thesupports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 160
5.15.2 Remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 161
5.15.3 Disengaging the transfer gearbox power take−off . . . . . . . . 5 163

214403175 VII
 Tableofcontents

5.16 Measures for preserving the value of concrete pumps and placing
booms in storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 —167

6 Index of key words

7 Glossary
G−1 Symbols for concrete pumps in accordance with German Mechanical
Engineering Association Standard (VDMA 24119) . . . . . . . . G  1

G−2 Key to the symbols for concrete pumps . . . . . . . . . . . . . . . . . G  7

G−3 Abbreviations and technical terms . . . . . . . . . . . . . . . . . . . . . G  15

VIII 214403175
 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 Türkiye
Putzmeister Makine Sanayi Ve Ticaret A.S.
G.O.Pasa Mah. Namik Kemal Bulvari No:6
59500 Çerkezköy/Tekirdag
Telefon +90 282 735 10 00
Fax +90 282 735 10 01
email: pm@putzmeister.com.tr

Hastane Mah. Hadimköy Istanbul Cad. No:62

Hadimköy / Arnavutköy Istanbul
Telefon: +90 212 771 55 00 (6hat)
Fax +90 212 771 55 09

or the Branch or Works Agency that looks after you.

Address:

Telephone:

Telefax:

e−mail:

TC01_001_1409EN
 GuidetotheOperatingInstructions

1.1 Foreword These Operating Instructions are intended to familiarize the user with
the machine and to assist him in using the machine properly in vari
ous operations.

The Operating Instructions contain important information on how to

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

The Operating Instructions are to be supplemented by the respective

national rules and regulations for accident prevention and environ
mental protection.

The Operating Instructions must always be available wherever the

machine is in use.

These Operating Instructions must be read and applied by any per

son in charge of carrying out work with and on the machine e.g.
− operation, including setting up, troubleshooting in the course of
work, evacuation of production waste, care and disposal of fuels
and consumables;
− service (maintenance, inspection, repair), and/or
− transport.

In addition to the Operating Instructions and mandatory rules and

regulations for accident prevention in the country and place of use of
the machine/plant, the generally−recognized rules of technology for
safe and proper working must also be observed.

BP01_002_0802EN 11
 GuidetotheOperatingInstructions

Should you have any questions following your study of the Operating
Instructions, the Branch or Agency serving you, or the Aichtal Works
will be happy to give you more information.

You will make it much easier for us to answer any questions if you
can give us the details of the machine model and the machine
number.

These Operating Instructions describe the vehicle superstructure

only. The Operating Instructions issued by the vehicle manufacturer
apply for the vehicle itself.

In the interests of constant improvement, modifications are made

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

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

tions intended for the machine will be replaced in full.

The reproduction, distribution and utilization of this document as well

as the communication of its contents to others without explicit author
ization is prohibited. Offenders will be held liable for the payment of
damages. All rights reserved in the event of the grant of a patent,
utility model or design.

© Putzmeister Condrete Pumps GmbH 1994

12 BP01_002_0802EN
 GuidetotheOperatingInstructions

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

" Task symbol

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

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

See also the maintenance cards:

This icon is used to refer to the maintenance cards required,
possibly as a supplement to the maintenance card you are currently
reading.

The following special tools are required:

This icon identifies the special tools necessary to carry out the work.
Normal tools, i.e. commercially−available tools or tools carried in the
truck, are not specially listed.

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

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

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

BP01_003_0601EN 13
 GuidetotheOperatingInstructions

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

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

of the danger precisely.

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

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

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

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

14 BP01_003_0601EN
 GuidetotheOperatingInstructions

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

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

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

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

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

BP01_003_0601EN 15
 2 Safety regulations

These safety regulations conform to the chapters Terms, definitions,

requirements" and Setting up and working with the machine" in the
German Engineering Federation (VDMA) brochure

Safety manual Concrete delivery and placing machines".

Here you will find a summary of the most important safety regula
tions. This chapter is particularly suitable as an initial basic instruc
tion for new employees.

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

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

information:
 EN12001, Conveying, spraying and placing machines for con
crete and mortar
 EN12100, Safety of machinery,
 EN602041, Electrical equipment of machines.
 in the Federal Republic of Germany: BGR182, Concrete pumps
and placing booms.

BP03_081_1101EN
 Safetyregulations

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

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

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

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

2.1.4 Arm assembly For the purposes of this safety manual, arm assemblies are powered
slewable devices consisting of one or more swinging or folding sec
tions for guiding the delivery line.

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

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

BP03_082_1401EN 21
 Safetyregulations

2.1.7 Truck mixer In this safety manual, truck mixers are vehicles with mixing equip
ment for transporting concrete.

2.1.8 Delivery line systems For the purposes of this safety manual, delivery line systems are de
fined as self−contained pipes or hoses in which concrete is pumped
from the concrete pump to the placement site. Devices for shutting−
off, diverting or cleaning delivery lines can be integrated into delivery
line systems.

2.1.9 Guiding the end hose The "end hose" as referred to in this safety manual is the hose that is
fitted on the arm assembly at the end of the delivery line for distribut
ing the concrete. There must be no couplings, spouts, discharge
stops or other items fixed to the outlet end of the end hose unless
they are approved by the manufacturer.

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

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

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

2.1.13 Hoseman Persons instructed by the site management in how an end hose is
guided. Hosemen must be able independently to evaluate danger
ous situations which may occur in the area of the end hose and react
according to the situation.

2.1.14 Signaller and other
auxiliary personnel
Persons instructed by the site management to help the machine op
erator in his work if the latter is unable to observe all areas of oper
ation and danger zones. Signallers must be able to independently
evaluate all dangerous situations which may occur when working
with a concrete pump and/or placing boom, and to react according
to the situation. The signaller must have a suitable means of com
munication with the machine operator.

22 BP03_082_1401EN

2.1.15 Truck mixer driver
2.1.16 Authorized inspector
2.1.17 Subject expert
2.1.18 Qualified personnel
2.1.19 After Sales Service
personnel
2.1.20 Maintenance
BP03_082_1401EN
Safetyregulations
Person who supplies the concrete pump with concrete from a truck
mixer. Truck mixer drivers must be instructed by the machine oper
ator to operate the operating elements on the concrete pump pro
vided for their use. Truck mixer drivers must be able to indepen
dently evaluate all dangerous situations which may occur when
working in the area of the hopper of a concrete pump, and to react
according to the situation.
Authorized inspectors are persons empowered by the relevant gov
ernment bodies to carry out this task of inspection. The prerequisites
for becoming an authorized inspector are:
− To have completed a higher education course in engineering or
similar.
− To have at least 5years’ professional experience in a relevant do
main, of which at least six months must have involved participation
in the work of an authorized inspector.
− To possess thorough knowledge of the relevant health and safety
regulations, as well as of directives and the generally recognised
rules of engineering.
− To have access to the necessary equipment to carry out the in
spection.
− To be able to carry out the tasks impartially.
For the purposes of this safety manual, a subject expert is a person
who, through their professional training, their professional experience
and their recent professional activity, has the required specialist
knowledge to inspect the tools.
Persons who have completed specialist training for a particular activ
ity which qualifies them to carry out their roles.
Qualified persons employed by the manufacturer who are respon
sible in particular for maintenance of the machine.
Maintenance embraces all measures required for inspection, servic
ing and repair of a machine.
23
 Safetyregulations

2.1.21 Place of work, working area, danger zone

Mobile machines
14 6 7
2

1 6

10

3
11

12
5

ab0005

Example

Stationary machines
14 11

4 10

4 9
3

3 6 6 1 2

13
13 13
1
5

11 12

ab0010

Example

24 BP03_082_1401EN
 Safetyregulations

No. 0 Designation Explanation

1 Machine operator In normal operation, with the remote control
2 Place off work
Pl k Hoseman At the end hose in the danger zone
(during pump
pump
3 Signaller In the machine operator’s range of vision
ing oper
oper
4 Auxiliary personnel As manual placing system operators
ations)
5 Truck mixer driver At the hopper in the danger zone
Area with a radius of the reach of the placing boom
6 Permitted
+ end hose length
Working area
The end hose must not be moved backwards be
7 Impermissible
yond the vertical of the placing boom
Risk of injury when pumping is started, during
pumping operations, when removing a blockage
8 At the end hose
and during washing out procedures. The diameter
of the danger zone is twice the end hose length.
Beneath the placing
9 Risk of injury from falling items
boom
Area of the support
legs and feet Danger of crushing when the machine is set up and
10 Danger zone
or area of the base when the supports are retracted
structure
Any presence on or below the machine when the
11 On the machine
pump is in operation is prohibited
Risk of injury during washing out procedures and
12 at the hopper
when the hopper is being filled using a truck mixer
Area of the delivery Hazard posed if lines burst, risk of injury from crush
13
line systems ing or shearing, particularly with gate valves
14 Structure or area being concreted Example

BP03_082_1401EN 25
 Safetyregulations

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

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

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

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

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

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

The working area must be secured and clearly identified. Suitable

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

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

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

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

Depending on the working situation, workplaces may occasionally

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

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

the machine whilst the machine is in use.

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

Support legs and There is a danger of crushing in the swingout and extension zone
support feet for the supports.

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

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

Guiding the end hose The danger zone when pumping is started, during pumping oper
ations, when removing a blockage and during washing out pro
cedures is the area around the end hose in which the hose may
swing out. The diameter of the danger zone is twice the end hose
length.

Hopper In the area of the hopper, there is a risk of becoming trapped be
tween the truck mixer and the hopper and of being sprayed with
concrete. There is a risk of being crushed and of injury by shearing
from the transfer tube. There is a risk of being entrapped by the ro
tating agitator.

Delivery line systems In the area around the delivery line systems there is a risk of injury
from the delivery line bursting if there is an abrupt rise in pressure.
There is a risk of crushing and injury by shearing with devices inte
grated in delivery line systems.

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2.2 Designated use The machine must only be operated as intended and in technically
perfect condition. All protective and safetyoriented devices, particu
larly removable protective devices and EMERGENCY STOP devices,
must be available and fully functional.

The machine is designed exclusively for the delivery and placing of

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

You must also observe the Operating Instructions and comply with
the intervals and conditions for inspections (particularly retesting)
and maintenance work in order to operate the machine within the li
mits of its proper use.

2.2.1 Retesting After initial commissioning of the machine, the operational safety of
the machine must be checked regularly by a subject expert. The in
spection intervals depend on the age of the machine. The older the
machine, the greater the probability of damage. This is why regular
retesting of the machine, appropriate to its age, is an effective
means for the early detection of damage.

Retesting must consist of the following:

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

Furthermore, information provided by the manufacturer to the oper

ator with reference to special instructions for maintenance and in
spection must be observed.

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2.2.2 Inspection intervals The inspection intervals are fixed as follows:

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

Machines more than 5years old:

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

Machines more than 10years old:

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

The day of initial commissioning in accordance with the handover

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

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

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

Notwithstanding national legislation, the operator can be liable in the

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

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

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2.3 Use contrary to Any use of the machine which is not described in section 2.2,en
designated use titled Designated use", or which extends beyond the uses de
scribed in this section is deemed to be contrary to designated use.
The manufacturer accepts no liability for damage resulting from such
use. Some examples of conceivable uses that are contrary to the
designated use are given below.

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

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

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2.3.3 Removing obstacles The placing boom must not be used under any circumstances to re
move obstacles. This would overload the placing boom, causing
damage and endangering people.

2.3.4 Extending the reach It is prohibited to attach an extension (e.g. freely suspended cross
beam) to the end hose or placing boom tip in order to extend the
reach or to pump at an angle. Since the boom and the lifting equip
ment for the extension have differing pivot points and modes of con
trol, it is not possible to co−ordinate their movements.

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

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

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

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

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

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

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

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

delivery sure greater than 85 bar) through the delivery line of the placing
boom. Delivery line elements are marked with the maximum permiss
ible delivery pressure. The delivery line and end hose are only suit
able for concrete pressures of up to 85 bar until the wear threshold is
reached. For the wear threshold, refer to the Operating Instructions
for the machine.

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

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

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

validated in the following situations in particular:
− use contrary to designated use
− incorrect operation, maintenance and repair
− use of spare parts or accessories other than original manufac
turer’s spare parts and accessories or their equivalents
− conversions, alterations or modifications to the machine
− fitting of accessories and attachments not approved by the manu
facturer
− adjustment of safety pressures, speeds of movement, power out
puts, speeds of rotation and other settings to values other than
those set in the works

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2.5 Personnel The operator must ensure that only persons who are qualified or
have received the necessary instruction work on or with the machine.
He must clearly define who is responsible for operation and mainten
ance of the machine. He must also ensure that only persons commis
sioned to work on the machine do so.

2.5.1 Requirements Persons operating or carrying out maintenance work on the machine
must meet the following requirements:
− They must be aged 18 years or over.
− They must be physically and mentally capable.
− They must be physiologically capable (rested and not under the
influence of alcohol, drugs or medication).
− They must have been instructed in the operation and maintenance
of the machine.
− They must have demonstrated their competence to the operator.
− They can be expected to reliably execute the tasks with which
they are charged.

The operating personnel must not wear loose garments or jewellery,

including rings. Long hair which is not tied back must be covered by
a hair net. There is a risk of injury, in particular from being caught or
trapped by moving parts.

2.5.2 Qualifications Do not allow persons who have not yet completed training or instruc
tion, or persons taking a general training course, to operate the ma
chine unless under the constant supervision of an experienced per
son.

If you do not have qualified personnel, suitable workshop equipment

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

2.5.3 Responsibility of the The operator must define the responsibility of the machine operator
machine operator (including in respect to national road traffic regulations) and em
power him to reject instructions from third parties prejudicial to
safety. The machine operator must be able to reject the site of oper
ations if he has doubts regarding technical safety.

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2.6 Operating Instructions, operating procedures and other regulations

2.6.1 Operating Personnel entrusted with work on the machine must have read the
Instructions Operating Instructions, in particular the chapter on safety, before be
ginning work. Reading the instructions after work has begun is too
late. This applies especially to persons working only occasionally on
the machine, e.g. during setting up or maintenance.

The Operating Instructions and check book must always be kept to

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

As the operator, you must always make sure that the Operating In
structions are available. Have personnel working on the machine
confirm in writing their knowledge, understanding and application of
the Operating Instructions and Safety Regulations. At regular inter
vals of at least once a year, check that personnel are conscious of
safety and the hazards involved in their work and are taking account
of the Operating Instructions.

Personnel entrusted with work on the machine must observe all

safety instructions and hazard warnings, and must be familiar with
the machine itself. You must practice all the operating procedures
described in the Operating Instructions (extending the supports, op
erating the placing boom, shifting the placing boom into the driving
position, preparing the vehicle for moving, etc.) under the supervi
sion of a subject expert until you are certain you can execute them
safely. Ask questions if there is something you have not understood.
Begin operating the machine only once you are familiar with the lay
out and significance of all the control and monitoring devices and
the functioning of the machine in general.

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

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

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

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

requirements of the specified standards.

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

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

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

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Protective gloves
Protective gloves protect your hands against aggressive or chemical
substances, as well as against mechanical effects (e.g. impact) and
cutting injuries.
(DINEN388; Protective gloves against mechanical risks;
Class 1111)

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

Safety harness
When working at height, use the climbing aids and working platforms
provided for reasons of safety or wear a safety harness. The relevant
national regulations must be complied with.
(DINEN361; Personal Protective Equipment Against Falls from a
Height − Full Body Harnesses;
CategoryIII)

Face mask and respiratory protection

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

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2.8 Before starting work

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

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

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

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

Never leave the machine when the engine is running or when the en
gine could be started by an unauthorized person. If you need to
leave the machine, proceed as follows:
− switch off the remote control,
− disconnect the remote control and lock it away,
− switch off the ignition or the main switch,
− lock the control cabinet.

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2.9 Danger due to high–voltage

2.9.1 High–voltage lines Whenever you touch a high−voltage line, there is a risk of death for
all persons either on the machine or in its vicinity or who are con
nected to it (via the remote control, end hose, etc.). A spark can
jump across from a high−voltage line even if you just approach it and
this will energize the machine and the surrounding area.

2.9.2 Discharge voltage In the event of a flash over, what is known as a discharge voltage
pattern pattern" is formed in the vicinity of the machine. The voltage de
creases from the inside to the outside in this discharge voltage pat
tern. If you step within this discharge voltage pattern, you will bridge
different potentials. This will cause a voltage corresponding to the
potential difference to flow through your body.

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

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

Rated voltage [V] Minimum clearance [m]

up to 1 kV 1,0

1 kV to 110 kV 3,0

110 kV to 220 kV 4,0

220 kV to 380 kV 5,0

unknown rated voltage 5,0

The specified clearances are minimum requirements. You must ob

serve any greater clearances that may be specified in the country of
use.

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

age lines and the placing boom swaying in the wind must also be
taken into consideration. You should further note that where air hu
midity is high, clearances greater than the minimum clearances
shown above are always necessary.

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

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

The same minimum clearances are necessary when driving under

overhead cables.

In the event that this minimum clearance cannot be maintained

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

Should you have any doubts, it is better to forego the use of the plac
ing boom and to lay a separate delivery line, for instance.

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2.9.4 High–voltage warning According to the current rules of engineering, high−voltage warning
devices devices do not meet a safety standard which enables a safe under
shooting of the required minimum clearances to high−voltage lines.
Previous experience has shown that high−voltage warning devices
cannot make all situations in working procedures safe. Flash overs
and fatal accidents can occur despite the use of a high−voltage
warning device. You must therefore always maintain the minimum
clearances mentioned above.

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

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If your machine comes into contact with heavy current lines:

− Warn those outside against approaching and touching the ma
chine.
− Have the power switched off.
− Only leave the machine once you are sure that the line you have
touched or damaged has been de−energized.

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Power stations are always equipped with automatic switch−on de

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

You should only move and rescue injured persons once a represen
tative of the power station has notified you that the cable has been
switched off.

A radio remote control system only protects the machine operator if

he is standing outside the discharge voltage pattern.

2.9.6 Earthing in the event Faults can be caused in the radio remote control system and dan
of electrostatic gerous electrical charging of the machine can occur when working
charging in the vicinity of transmitters (radio transmitter, etc.). Persons who
bridge the charged parts to the earth are heavily charged on con
tact.

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

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

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

age lines (see also page221) must be maintained and the in
structions regarding storms and bad weather (see also
page239) must be observed.

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

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2.10 Stationary machines

2.10.1 Set-up site Stationary machines are generally used on a construction site for a
lengthy period. For this reason, site management should prepare the
setup site carefully. The site management must deliver the necess
ary documents in good time in order to be able to prepare the
foundations, base plates or similar on time.

When selecting the setup site, remember that the machine must be
dismantled and transported away again at the end of its use on site.
The ambient conditions may change as construction work prog
resses.

2.10.2 Stationary booms Stationary booms can be erected on tubular columns, lattice booms
or other base structures. The base/structural elements to which the
base structure is fixed must be able to withstand the forces and mo
ments transferred via the base structure, as specified in the manu
facturer’s information. The base frame of the base structure must be
fastened in place so that it is level on the base/structural elements in
every direction. Check the documentation provided by the manufac
turer in this regard and the corresponding notes in the operating in
structions.

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2.10.3 Lifting machines and
components
Machines which are transported to the setup site in individual parts
or not under their own power must only be lifted with suitable lifting
equipment in accordance with the specifications in the Operating
Instructions. The lifting gear on the machine must be capable of ac
cepting the lifting gear and lifting the load. Noone should stand
under suspended loads. Before work is started, a subject expert
must check that the assembled machine is working properly.

2.10.4 Loading and Only use suitable means to load and transport stationary machines.
transporting Ensure that noone can be injured by the machine tipping over or
slipping.

If there are transport fixtures provided for the machine or its individ
ual components, only these should be used. The machine/compo
nents must be properly secured during transport. The transport ve
hicle and machine must be marked to conform with the road traffic
regulations in the country concerned if they are to use the public
highway.

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2.11 Mobile machines

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

As machine operator, you must familiarise yourself with the working

area and surroundings before work is begun. The working area and
surroundings include, in particular, obstacles in the work and travel
ling areas, the loadbearing capacity of the supporting ground and
any barriers separating the construction site from public roads.

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

Incidents of overlapping with the working areas of other machines

(particularly cranes, other placing booms, etc.) should be avoided
as far as possible. If this is not possible, special care and attention is
required when setting up and operating machinery. If necessary, you
must use a signaller.

You must also check the approach route to the site where the ma
chine will be set up. If you are unsure whether the approach route is
suitable, prepare the route before work is started. It is especially
necessary to walk the approach route once in darkness and at dusk
or dawn. You should repeat this exercise again before leaving the
construction site.

You must always ask for a signaller if you have to reverse. If necess
ary, have the approach route closed off or secured by signallers.
Have any materials or equipment that hinder your approach re
moved.

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2.11.2 Supporting ground Check the loadbearing capacity of the supporting ground. The site
management will be able to state the permitted ground pressure.

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

a level surface on top of the uneven ground. There must be no voids
or other ground irregularities under the support feet. Asphalt, con
crete slabs, etc. may have been washed out underneath. Never set
the machine up on backfilled ground.

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

timber blocks may be used to increase the support area. The sup
port timbers must be undamaged and free from ice, oil, grease, etc.
The support blocks and timber blocks must be laid under the sup
port plates such that the load is distributed uniformly and the sup
port leg cannot slip off the side of the support.

Check the stability of the machine regularly during operation. Inter

rupt the pumping operation if the machine becomes unstable. Fac
tors which reduce stability include, for instance:
− Modifications to the ground conditions, particularly caused by rain
water or the thawing of frozen ground
− the support sinking on one side
− fluid losses through leaks in the support hydraulics

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

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The force transferred to the ground by each support leg diffuses

through the soil in a conical pattern at an angle of 45_. Safe clear
ance to the pits and slopes must be maintained, and such clearance
must be determined in accordance with the nature of the ground.
The safe clearance is measured from the foot of the pit.

However, for undisturbed, compacted ground, the safe clearance

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

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

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

Swing out and telescope the support legs to their end positions in
sequence. Intermediate positions are prohibited to guarantee stabil
ity. Exceptions are machines which have been equipped by the
manufacturer with a device which allows secure erection with a re
duction in support. Check the corresponding notes in this regard in
the operating instructions.

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

stopped, the entire volume of fluid is available for the remaining
movements, and can increase their speeds. Depending on the de
sign, it may be the case that carrying out several movements at once
(as opposed to carrying out a single movement at maximum speed
at any one time) does not bring any advantage in terms of time.
Carrying out several movements at once requires an increased level
of attentiveness.

Lock all supports mechanically, if this is provided for in the design.

Close all shutoff valves in the support hydraulics. Leaks can cause
the supports to sink on one side.

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The machine must be made level in all directions. The maximum per
mitted deviation from the horizontal is 3_. Greater deviations from the
horizontal overload the slewing gear for the placing boom and jeop
ardize the stability of the machine.

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Check stability regularly during operation. The elastic distortions to

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

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2.11.5 Driving When preparing the machine for driving, you must perform the fol
lowing tasks in particular:
− The placing boom must be folded in fully and positioned on the
placing boom support provided.
− The support legs and support feet must be fully retracted and se
cured.
− Raised or locked axles must be lowered and released.
− Accessories and moving parts belonging to the machine must be
safely stowed/secured.
− The maximum permissible gross weight may not be exceeded.

While the vehicle is being driven, the delivery line, pump and hopper
must be empty. If there are concrete leavings in the hopper, it must
not be possible for the leavings to be thrown out while the vehicle is
in motion, thereby creating a risk of injury. You must adapt your driv
ing style to the altered centre of gravity of the machine. You must not
exceed the maximum permissible gross weight of the machine. Ob
serve the road traffic regulations and specifications of the machine
manufacturer.

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

struction pits and at least 2m from slopes.

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Always make sure that there is sufficient clearance when driving

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

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

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

Observe national road traffic regulations. If necessary, clean the

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

Persons accompanying the driver must be seated on the passenger

seats provided for this purpose.

Whilst the truck is in motion, the mixer drum on truck mixer concrete
pumps must only be rotated at the maximum speed of rotation speci
fied in the Operating Instructions. The truck is at risk of tipping over,
particularly when travelling round corners.

2.11.6 Towing The machine must only be towed, loaded and transported in accord
ance with the Operating Instructions. Only use existing towing
hitches for towing and observe the truck manufacturer’s regulations.

You must comply with the prescribed driving position, permitted

speed and itinerary when towing.

BP03_082_1401EN 233
 Safetyregulations

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

wz0176

Use only appropriate means of transport and lifting equipment of ad

equate loadbearing capacity. Lifting equipment, lifting tackle, sup
port trestles and other auxiliary equipment must be reliable and safe
in operation.

Use only stable loading ramps of adequate loadbearing capacity for

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

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

234 BP03_082_1401EN
 Safetyregulations

2.12 Placing booms

2.12.1 Unfolding the placing Only raise a mobile placing boom from the driving position once the
boom machine has been supported in accordance with the Operating In
structions. Stationary booms may only be raised after the proper
set−up has been checked by a subject expert.

Only raise the placing boom in the sequence described in the Oper
ating Instructions. The correct sequence depends on the folding sys
tem (roll−and−fold system, Z−fold system, etc.).

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

stopped, the entire volume of fluid is available for the remaining
movements, and can increase their speeds. Depending on the de
sign, it may be the case that carrying out several movements at once
(as opposed to carrying out a single movement at maximum speed
at any one time) does not bring any advantage in terms of time.
Carrying out several movements at once requires an increased level
of attentiveness.

The range of a radio remote control is great enough for the machine
to receive control commands (e.g. from a great distance, from inside
enclosed spaces), even without visual contact. If there is no visual
contact, for example, because you are changing workplace, you
must switch off the remote control. If there is no visual contact, for
example, because the construction site is unclear, signallers MUST
be used, and must remain in contact with the machine operator
using suitable means, and have visual contact with the site of con
crete placement, work areas and danger zones, and the machine.

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

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

BP03_082_1401EN 235
 Safetyregulations

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

Press the EMERGENCY STOP button immediately if the placing

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

wz0056

Placing booms with placing boom hinges which allow considerable

flex angles have a very large potential working area. Because of this
high manoeuvrability, various placing booms can, however, also be
shifted into positions that are of no interest for the pumping oper
ation.

There is a risk that you will damage the truck, truck superstructure or
obstacles on the construction site with the placing boom. Under cer
tain circumstances it is even possible to overload or cause damage
to the placing boom. Uncontrolled movements may result from the
sudden, violent release of the placing boom after collisions. This may
also result in (possibly fatal) personal injury.

The manufacturer has indicated such impermissible working areas

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

236 BP03_082_1401EN

2.12.2 Guiding the end hose
BP03_082_1401EN
Safetyregulations
The end hose must hang freely each time you start pumping, when
you start pumping again after blockages, and during washing out
procedures. Noone should stand within the danger zone of the end
hose. The diameter of the danger zone is twice the end hose length.
Do not guide the end hose when pumping is started. There is a risk
of injury from the end hose swinging out or stones being ejected.
wz0136
If a longer end hose is used, the diameter of the danger zone is also
increased (see also page212).
End hoses with a length of more than 4m must not be guided by
hand.
There is a risk of injury to the hoseman if the end hose becomes
caught in the reinforcement and suddenly jumps out on further
movement of the placing boom.
237
 Safetyregulations

Never bend the end hose over. Never attempt to straighten a bent
end hose by increasing the pressure. The end hose must not be sub
merged below the surface of the concrete being delivered, otherwise
the concrete may spray upwards.

The concrete may also spray from the end hose due to the presence
of air in the delivery line. To prevent this from occurring, the hopper
must always be filled with concrete as far as the agitator shaft so that
no air can be sucked in.

The end hose must be secured against falling.

2.12.3 Guiding the end hose The hoseman must guide the end hose in such a way that prevents
ergonomically excess spraying of concrete, and so that concrete is directed pre
cisely into the site of concrete placement.

Control the placing boom so that the hoseman can guide the end
hose without power consumption. The hoseman must not carry the
end hose by hand, because the weight of it may cause permanent
personal injury.

238 BP03_082_1401EN
 Safetyregulations

2.12.4 Procedure in storms Return the placing boom to the driving position in the event of storms
or bad weather.
− Placing booms with a vertical reach of 42m or more may only be
operated in wind forces up Windstärke7 (wind
speed51km/h=14m/s).
− Placing booms with a vertical reach of less than 42m may only be
operated in wind forces up to8 (wind speed74km/h=20m/s).

Wind speeds in accordance with the Beaufort scale are average

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

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

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

Tower cranes on construction sites generally have wind speed

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

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

In addition, such minus temperatures should be considered the real

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

BP03_082_1401EN 239
 Safetyregulations

2.13 Delivery line systems

2.13.1 Suitable delivery lines
Use only delivery lines, end hoses, couplings, etc. which are in per
fect condition and suitable for the delivery job, and have been ap
proved by the machine manufacturer. Delivery lines are subject to
wear which varies according to the pressure and composition of the
concrete, the material from which the delivery line is made, etc.

2.13.2 Securing delivery Delivery lines, delivery hoses, end hoses and couplings must be se
lines curely fastened and secured against spontaneous opening.

wz0066

240 BP03_082_1401EN
 Safetyregulations

2.13.3 Tightness and Regularly force water through the delivery line under operating pres
blockages sure to check that the system is watertight.

wz0047

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

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

Prevent blockages by adjusting the operating conditions. Remove

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

BP03_082_1401EN 241
 Safetyregulations

2.13.4 Opening delivery lines You must not open or tap delivery lines while these are pressurized.
Concrete exiting under pressure can cause injury. The concrete col
umn must be depressurized by reverse pumping before the delivery
line is opened. Never work bending directly over the coupling.

wz0076

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

2.13.6 Fastening delivery Delivery lines, in particular riser lines which are not laid along plac
lines ing booms, must be securely fastened in order to transfer the forces
generated in them into the structure or other structural members. The
lines must be laid so as to avoid kinks, sharp bends, stresses and
damage during pumping operations.

242 BP03_082_1401EN
 Safetyregulations

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

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

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

2.13.8 Devices for shutting– During operation there is a risk of being crushed and of injury by
off, diverting or shearing. Hydraulically driven devices are generally supplied with
cleaning delivery lines power by a machine’s hydraulic system. It must therefore be poss
ible to see from the devices and the machine with control unit and
vice versa. Observe the safety regulations for the machine and the
device when connecting and operating a device. Make sure that no−
one is in the danger zone before operating devices.

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

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

BP03_082_1401EN 243
 Safetyregulations
2.14 Pumping operations
2.14.1 Place of work
2.14.2 Safety
2.14.3 Remote control
244
The machine operator’s place of work is with the remote control when
the pump is in operation. If you operate the machine using the re
mote control, all operating and control devices on the machine must
be closed to prevent unauthorized interventions.
In the case of stationary placing booms, platforms or similar equip
ment are only provided for assembly and maintenance work. Use of
these platforms as a workplace during operation is prohibited.
It is forbidden to climb onto the machine during operation. In the
case of stationary placing booms, it is forbidden to climb ladders
during operation.
Before switching on or restarting the machine or individual machine
functions, you must ensure that doing so will not endanger anyone’s
safety.
Refrain from any procedures that may impair the stability of the ma
chine or are prejudicial to safety in any other way.
You must always carry the remote control on your person when the
machine is ready for operation. Only in this way can it be guaranteed
that you can press the EMERGENCY STOP button in the event of an
emergency situation. The EMERGENCY STOP button may only be
unlocked once the cause/emergency has been remedied.
As a general rule, you must carry the remote control so that no con
trol elements are activated unintentionally. If your attention is drawn
away from the machine (particularly when changing workplace), you
must switch off the remote control.
During breaks in pumping, interruptions, maintenance work, or be
fore you leave the machine, you must secure it against unintended
movements and unauthorized use. Switch off the remote control and
lock it away.
BP03_082_1401EN

2.14.4 Moving machine
components and
hot surfaces
2.14.5 Constant observation
of the machine
2.14.6 Truck mixer
BP03_082_1401EN
Safetyregulations
Keep all access covers, maintenance flaps, guards, etc. closed and
locked during operation. This also applies in particular to the grille,
water box cover and covers over cylinders. There is otherwise a risk
of injury from moving parts of the machine and a risk of burning on
hot surfaces. In particular, there is a risk of burns from the engine,
attached parts and the exhaust.
Never start work unless the grille is closed and bolted down or other
wise secured.
Do not touch moving parts of the machine, whether the machine is
running or switched off. Always switch off the engine first, and dump
the accumulator pressure where an accumulator is fitted.
Never poke any objects (e.g. a shovel handle, trowel or similar) into
moving machine components. Such objects could become trapped
and dragged into the machine. They might then hit you or be torn
from your hands and cause you injury.
You should be constantly observing the machine for any damage or
faults while it is in use. In the event of faults or malfunctions that im
pair safety at work, shut the machine down immediately and secure
it. Have the faults rectified immediately. If it is not possible to rectify
faults which jeopardize the safe operation of the machine, you must
suspend operations until the defects are rectified.
As the machine operator, it is your role to instruct the truck mixer
drivers who deliver the concrete to you, so that they are able to oper
ate the operating elements on the concrete pump provided for their
use. Only allow the truck mixer drivers to work alone once you are
certain that they have understood your instructions.
Make sure that no−one stands between the approaching truck mixer
and the machine. There is a danger of being crushed between the
truck mixer and the machine.
245
 Safetyregulations

2.15 Cleaning

2.15.1 General You must drain the delivery line, pump and hopper completely. Con
crete leavings in the hopper, in particular, may be thrown out whilst
the truck is moving.

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

wz0156

The preferred methods for cleaning the delivery line are reverse
pumping or forced cleaning with water. The agitator must be
switched on during reverse pumping. Otherwise, the concrete flow
ing back into the hopper can bend the agitator shaft. Use a catch
basket, pipe cleaning head and wash−out ball for forced cleaning to
prevent any water from flowing into the formwork.

Never spray remote controls or control cabinets with barrier agents

(mould oil or similar) to protect them against contamination. This
causes significant corrosion damage to the electrical system.

246 BP03_082_1401EN
 Safetyregulations

2.15.2 Cleaning agents Take care when using aggressive cleaning agents. Aggressive
cleaning agents may attack materials (e.g. rubber) and painted sur
faces. You can use commercially available paint cleaning and care
agents, as long as these have a pH value of between 4 and 9. Ask
the manufacturer of the cleaning agent to confirm its suitability. Ob
serve the manufacturer’s instructions regarding use and safe handl
ing. Wear protective clothing. Always rinse off cleaning agent thor
oughly with clean water; do not allow puddles to form.

wz0146

Do not use sea water or other water containing salt for cleaning pur
poses.

Do not use any highly flammable agent for cleaning; there is a

danger of fire.

2.15.3 Hazards There is a risk of injury at all points on the machine from slipping,
tripping, bumping into things, etc. Use the handles and steps to
climb into and out of the machine. It is forbidden to stand on the
grille. Do not jump from the machine.

Do not reach into the hopper or any other moving machine compo
nents. This rule must also be followed when you are opening the
outlet on the bottom of the hopper. Do not remove the grille.

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

BP03_082_1401EN 247
 Safetyregulations

2.15.4 Cleaning with When the delivery line is being cleaned with compressed air, there is
compressed air an increased risk of accident from explosively escaping compressed
air, spurting concrete and flapping delivery or end hoses if they have
not been removed.

Compressed air should only be used for cleaning purposes under

the supervision of a subject expert. All persons participating in the
cleaning procedure must be instructed in the safety regulations.

The manufacturer accepts no liability for damage caused by incor

rectly performed compressed air cleaning. If you blow out the deliv
ery line with compressed air, you must observe the following rules
without fail:
− Individual pipes and short pipe runs up to 10m in length must not
be blown through with compressed air. There is a risk of accident
from rebound.
− Only blow out delivery lines which have the same nominal diam
eter throughout their length. Reducer pipes must be drained and
flushed out by hand.
− No bends, delivery or end hoses may be fitted at the end of the
delivery line.
− A catch basket must be fastened at the end of the delivery line
and a wash−out adaptor must be fitted on the head of the delivery
line. Catch basket and wash−out adaptor must fit the delivery line
system.
− The concrete must be able to flow freely from the end of the deliv
ery line.
− No persons may be present in an area of 3m around the delivery
line, at the end of the delivery line and especially in front of the
opening in the catch basket.
− Care must be taken to ensure that any concrete that might be ex
pelled from the catch basket cannot injure anybody or cause any
damage.

248 BP03_082_1401EN
 Safetyregulations

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

cock and a pressure gauge.
− The pressure gauge must be kept under constant observation dur
ing the cleaning process. The pressure in the delivery line must be
rapidly dumped via the dump cock in the event of a sudden drop
in pressure (concrete column exiting from the end of the line) or
increase in pressure (risk of blockage).
− The sponge ball or the plug used to push the concrete out must
be sufficiently dense that the air does not pass through it into the
concrete. In addition, the delivery line must be sealed to the rear
when the sponge ball or plug is caught in the catch basket.
− Only work on the delivery line (particularly when opening the deliv
ery line) if it has been depressurized. Make sure that the com
pressed air has been dumped completely.
− The dump cock must be opened in such a way that no−one can
be injured by concrete residue that might be expelled from the
dump cock.

2.15.5 Protection against Water spraying on the machine from random directions has no dam
water aging effect. The electrical system is protected against spray water,
but is not waterproof.

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

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

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

Look out for leaks, loose connections, chafe marks and damage dur
ing the cleaning procedure. Any identified defects must be rectified
immediately. The machine must be greased after it has been
cleaned using a high−pressure cleaner.

BP03_082_1401EN 249
 3 General technical description

This chapter describes the components and assemblies on this

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

BP02_001_0302EN
 Generaltechnicaldescription

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

Left truck side

1
ÁÁ
2 3 4 5 6 7 8 9 10 11 12

ÁÁ BP23_141_1212EN 1

No. 0 Component Page

1 Documentation accompanying the machine
Radio and/or cable remote control 368
2
Ergonic Graphic Display − Remote Control (EGDRC) 375
3 OSS−lamp 321
Boom functions emergency control levers 3126
4
(in the stowage compartment)
5 Left support control block 3123
6 End hose (on the boom tip) 3130
7 Flushing water pump (on the water tank) 3136
Accumulator dump valve 3127
8
Agitator and water pump control block 3127
9 Vibrator (on the grille) 3139
10 Transfer tube 314
11 Underride protection
12 Agitator safety cutout 3120

BP23_141_1212EN 31
 Generaltechnicaldescription

Right truck side

1 2 3 4 5 6 7 8 9 10

BP23_141_1212EN 2

No. 0 Component Page

Mushroomhead button for horn on the boom
1
(on the side of the hopper)
2 Control panel (in the steps) 366
Pump control system 3127
3
Transfer tube damping 3127
4 Magnetic switches distributor casing 3116
5 Hydraulic fluid radiator 3140
6 Right support control block 3123
Control cabinet (in the stowage compartment) 319
7 Ergonic Graphic Display (EGD) 322
EPS computer (Ergonic Pump System)
8 OSS−lamp 321
9 Machine rating plate 37
10 Boom rating plate 38

32 BP23_141_1212EN
 Generaltechnicaldescription

3.2 Safety equipment This illustration shows examples of safety equipment which may be
fitted on the machine. The mounting location may differ on different
machine models (e.g. other side of the truck).

1 2 3 4 5 6 2 7

BP21_611_0904EN 1

No. 0 Safety equipment

1 EMERGENCY STOP button / STOP button on the remote control
2 Snaplock on the support leg
3 Retaining rope on the end hose
EMERGENCY STOP button
4
Two−hand control device for the support legs
5 Water box cover
Ventilation of air−sprung axles
6
Locking of lifting axles
7 Cover over the switch cylinders

BP21_611_0904EN 33
 Generaltechnicaldescription

BP21_611_0904EN 2

No. 0 Safety equipment

1 Securing cotter pins on the delivery line couplings
2 Spray guard
3 Grille on the hopper

34 BP21_611_0904EN
 Generaltechnicaldescription

1 2 3 4 5 6 7 4

BP21_611_0904EN 3

No. 0 Safety equipment

1 Agitator safety cutout
2 Mechanical grille securing device
3 Cover over the switch cylinders
4 Snaplock on the support leg
EMERGENCY STOP button
5
Two−hand control device for the support legs
Toggle switch for Local control − 0 − Remote control
6
OSS equipment
7 Cover over the boom functions control block

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

Check the safety equipment as described in the Operating Instructions.

BP21_611_0904EN 35
 Operation

3.3 Technical data You will find the technical data and setting values for your machine
inthe test reading supplied. You will find the most important data in
brief on the rating plates attached to the machine and to the boom.

3.3.1 Electromagnetic The certificate of compliance with EMC protection requirements

compatibility (EMC)
hasbeen issued in accordance with Article 6 paragraph 2 of
CouncilDirective 2004/108/EC on the approximation of the laws
ofthe member states relating to electromagnetic compatibility,
implemented in Germany by the law concerning the electromagnetic
compatibility of equipment, dated 26th February 2008 (EMVG,
section 4).

Customer: PutzmeisterAG
MaxEythStrasse10
72631Aichtal, Germany
To be inspected: Concrete pump control system
withZMSEPS
Test location: EMCtech GmbH, Waiblingen,
Absorberhalle
Test report no.: P060556a
Date of testing: 31st March 2009

Inspection type Individual tests Basic standard System Requirement Result

Emission − Radio interference field intensity EN 13309:2000 30 − 1000 MHz Broadband − A.1 passed
radiated inter Narrow band A.3
ference (SA)
EN 13309:2000
Immunity − RF field, AM − modulated ISO 114512 20 − 1000 MHz 30 V/m Peak = passed
interference 17 V/m + AM
resistance (SF) 80%/1kHz
EN 13309:2000
13309 2000
Vehicle voltage pulses ISO 76372 1, 2, 3a, 3b Degree of severity I passed
on cable remote control Function status A
Electrostatic discharge (ESD) ISO TR 10605 Criterion B
a) direct contact a) 4 kV a) passed
b) direct air b) 4 kV b) passed

Compliance with the fundamental requirements of the EMC Directive

was confirmed on the basis of the documentation described in test
report no. P060556a. The inspections carried out with regard to
radiated interference and interference resistance were passed.

36 BP22_840_1003EN
 Generaltechnicaldescription

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

PutzmeisterMak.San.veTic.A.S.
G.O.PasaMah.NamikKemalBul.No:6
PK−59500Çerkezköy/Tekirdag
Turkey 2018 5

1 Betonpumpe
2 BSF 38–5.12 H NG

3
214403175
4 6

7 8

TC22_830_1111EN 1

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

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

TC22_830_1111EN 37
 Generaltechnicaldescription

3.3.3 Boom rating plate The following plate is attached to the boom:

PutzmeisterMak.San.veTic.A.S.
G.O.PasaMah.NamikKemalBul.No:6 Turkey 10 637753 15 242838001
PK−59500Çerkezköy/Tekirdag
11 125 16 125
1 M 38−5
12 132x4,5
13
2
174402581 14 ST
3 633892 – 17 612253
– 18
125
4 2018 – 19
139,7x7,1
– 20
5 34 – 3408
– –
6 38
– –
7 4 – –
– –
8 350 – –
– –
9 85 – –

TC02_007_0809EN 1

38 TC02_007_0809EN
 Generaltechnicaldescription

No. 0 Placing boom data

1 Model
2 Placing boom no.
3 Material no. (MN)
4 Year of manufacture
5 Horizontal reach max.
6 Vertical reach max.
7 Length of end hose max.
8 Hydraulic pressure max.
9 Delivery pressure max.
Placing boom delivery line data
10 MN (material number)
11 DN (nominal diameter)
Model (maximum permitted outside diameter
12
and wall thickness of the delivery line)
13 Coupling type (AL=aluminium, ST=steel)
14 L1−L6: Arm assembly adapter pipe lengths
End hose data
15 MN (material number)
16 DN (nominal diameter)
Pump delivery line data
17 MN (material number)
18 DN (nominal diameter)
Model (maximum permitted outside diameter
19
and wall thickness of the delivery line)
20 V1−V10: Pump−riser pipe adapter pipe lengths

TC02_007_0809EN 39
 Generaltechnicaldescription

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

The place of work is from the remote control. The machine has a
sound pressure level of 85 dB(A) within a radius of 16m. Ear de
fenders must be worn in the vicinity of the machine since the sound
pressure level can be higher. The sound pressure was determined
on the basis of Directive 2000/14/EU.

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

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

117

BP21_359_1001EN 1

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

310 BP21_359_1001EN
 Generaltechnicaldescription

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

Sound pressure level In the past, the sound pressure level of the machine was stated. To
measure this level, the sound produced by the machine was
measured at several measuring points and at a fixed distance and
height. The average value was determined from these measure
ments and converted to a theoretical distance. The sound pressure
level stated for the machine therefore always referred to a theoretical
distance and was given in dB(A).

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

closer to the machine.

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

Advantage: as you approach the machine, although the sound pres

sure level increases, the surface area of the imaginary sphere de
creases. This means that multiplying the two figures gives the same
sound power level as before.

BP21_359_1001EN 311
 Generaltechnicaldescription

3.3.6 Reaches The M38−5 RZ has the reaches listed below.

BP23_137_1212EN 1

1 Horizontal reach from middle of slewing unit 32.8m

2 Horizontal reach from front edge of truck 30.3m
3 Vertical reach 37.5m
4 Unfolding height 7.4m
5 Depth of reach 25.3m
6 End hose 4m

312 BP23_137_1212EN
 Generaltechnicaldescription

3.4 Description of This section is intended to help you understand the functions of the
the functions machine so that you can restrict the field of the machine’s applica
tions to suitable areas and avoid errors in operation.

3.4.1 Boom The boom arms are of box construction. They are actuated hydrauli
cally.
Arm hinges with excellent angular range, in combination with the
powerful slewing gear with its wide slewing range, provide very flex
ible movement.

3.4.2 Delivery line The delivery and riser lines comprise standard straight pipe sections
and elbows. These are thus easily replaced.
Standard Putzmeister clamp couplings serve as both pivot joints and
pipe connectors.
The elbow pivot at the end of the boom acts as a brake on the falling
concrete and reduces the wear on the end hose. Thanks to its steel
corded fabric, this hose is suitable for an operating pressure of up to
85 bar.

3.4.3 Support legs The telescopic support legs swing out and are fitted with fully hy
draulic support cylinders thus giving the stability required.

3.4.4 Hydraulic control All boom movements are effected hydraulically. All boom cylinders
have two integral safety valves to provide protection against over
loading or rupture of the hydraulic lines.
The hydraulic fluid supply is sufficient to operate a number of cylin
ders simultaneously. The hydraulic control can be operated from the
concrete pump or by using a portable remote control unit.

The control valves are actuated:

− electrically; or
− electro−pneumatically; or
− electro−hydraulically.

The hydraulic fluid tank is integrated in the boom pedestal.

Compressed air and control current are taken from the truck.

BP02_074_9605EN 313
 Generaltechnicaldescription

3.4.5 Pump PM pumps are driven hydraulically through diesel engine powered
fluid pumps. The delivery pistons (4) are hydraulically linked together
through the driving cylinders (5). They operate in a push−pull mode.
The returning delivery piston sucks the concrete in. At the same
time, the advancing delivery piston forces the concrete sucked in
previously into the delivery line through the pressure pipe or the
pressure elbow (1).
The pump switches over at the end of the stroke. The transfer tube
(2) swings over the full delivery cylinder (3) and the delivery pistons
(4) reverse their direction of movement.

Reverse stroke
Reversal of the delivery pistons’ (4) movement in the middle of the
stroke movement. The transfer tube (2) does not switch. The con
crete is sucked back from the delivery line into the hopper.

Switchover
Reversal of the delivery pistons’ (4) direction in the middle of the
stroke movement. The transfer tube (2) switches over. The concrete
is still pumped without interruption. Switching over helps prevent the
formation of blockages.

3.4.6 S transfer tube

3
2
1

12501502

1 Pressure elbow
2 Transfer tube
3 Delivery cylinder
4 Delivery piston
5 Drive cylinder

314 BP02_030_9605EN
 Generaltechnicaldescription

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

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

Truck-mounted concrete pump standard

Output [m3]/year 30000
Operating hours [h]/year 400
Uses per day 3
Uses per year 750

Truck mixer concrete pump standard

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

stationary concrete pump standard

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

BP22_827_1212EN 315
 Generaltechnicaldescription

3.5.2 Site of use A concrete pump is designed for industrial use on outdoor construc
tion sites, or indoors with adequate ventilation. It must not be used in
areas where there is a potentially explosive atmosphere.

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

Pump type maximum height

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

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

316 BP22_827_1212EN
 Generaltechnicaldescription

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

temperature outside the given temperature ranges.

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

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

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

BP22_827_1212EN 317
 Generaltechnicaldescription

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

The electrical control devices may include the following components,

depending on the equipment on your machine.
− Control cabinet
− OSS equipment
− Control panel
− Centralized lubrication system
− Cable remote control
− Radio remote control system
− Distributor casing for inductive/magnetic switches

Note
Further control devices and components are described in the
Hydraulic control devices" (from page 3122) and Othercompo
nents" (from page 3129) sections.

318 BP02_388_9704EN
 Generaltechnicaldescription

3.6.1 Central modular The central modular control cabinet is illustrated below. You will find
control cabinet the description of any additional door modules and their control and
operating elements fitted in place of the blanking plates on the fol
lowing pages.

1 1

1 1

5
2 4

BP22_929_1110EN 1

Operating/ Belongs
No. 0 Meaning/Function
control element with no.:
1 Blanking plate Options for door modules
Locally latched toggle
2 Local control − 0 − Remote control
switch
3 Female connector Diagnosis
4 Ergonic Graphic Display Displaying and setting operating states
5 Female connector Connection for remote control

BP22_929_1110EN 319
 Generaltechnicaldescription

Special features of the control cabinet

Closing and locking the The control cabinet is located in a stowage compartment. You must
control cabinet always lock this stowage compartment to prevent any unauthorised
person switching the control system over.

Caution
Depending on the design, the stowage compartment cannot be
closed on some machines when the cable remote control is used. In
such cases, the machine operator must take suitable measures to
ensure that no unauthorized persons gain access to the control cabi
net.

Diagnostics socket To capture data from the machine, a diagnostics unit can be con
nected to the diagnostics socket by authorized and qualified person
nel.

Locally latched toggle To use a locally latched toggle switch, you must first pull it out and
switches then push it towards the symbol.

Switchover from local to The EMERGENCY STOP circuit is activated automatically when you
remote control switch over from local to remote control. You must operate the horn
to deactivate the EMERGENCY STOP circuit.

320 BP22_929_1110EN
 Generaltechnicaldescription

3.6.2 OSS equipment The door module for the OSS equipment (OSS = One−Side−Support)
is illustrated below. This equipment allows the machine to be set up
in a narrow space. The flashing OSS−lamps for the working range
are attached to the boom pedestal at the front.

1 2 3 4

BP23_144_1212EN 1

No. Operating/ Belongs

0 control element
1 Green indicator lamp
2 Keyswitch
3 Green indicator lamp
4 Toggle switch
Meaning/Function
with no.:
OSS−working area: selected, left
OSS−working area: selecting
OSS−working area: selected, right
OSS−working area: acknowledging
OSS−lamp: switching off

BP23_144_1212EN 321
 Generaltechnicaldescription

3.6.3 Ergonic Graphic The Ergonic Graphic Display (EGD) is a graphic display and
Display controlunit on the control cabinet. The EGD allows you to determine
the operating state of the machine. You can use the EGD operating
elements to navigate in the menu structure and to make settings.

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

Colour / Appearance Meaning

white background Standard appearance
green background Function is active
yellow background Limit reached, warning
red background Fault
The fault must be remedied before
the operation can be restarted on
themachine.
black frame Standard appearance
redblack frame The symbol can be selected, the
(thin line) sensor can be deactivated due to
fault and emergency operation can
be activated
red frame The symbol is selected
(thick line)
struck through The sensor is deactivated
flashing Fault
The fault can be overridden by
deactivating the sensor; the machine
with then go into a defined emerg
ency operation.

322 BP22_949_1104EN
 Generaltechnicaldescription

EGD and operating

elements

3
1

5 5 5
BP22_949_1104EN 1

Operating/
No. 0 Function / meaning
control element
Ergonic Graphic Display Menudriven displays and adjustable functions are
1
(EGD) shown in the EGD.
2 Pushbutton HOME" function key
3 Pushbutton Help" function key
Function button F4 for selecting or setting symbols and
4 Rotary/pushbutton
numerical values.
5 Pushbutton Function buttons F1, F2, F3 for navigating between
menus

BP22_949_1104EN 323
 Generaltechnicaldescription

Using the menus

The HOME" function key takes you back to the HOME" menu
fromany of the submenus.

The Help" function key displays a help screen for each menu.

You can navigate in the menu structure using function buttons F1,
F2, F3 and F4.

Use function button F4 to set selectable functions as follows:

" Turn F4 to select a function.

å The function is then framed in red (thick line).

" Then press F4 to activate the selected function.

å The function flashes.

" Now turn F4 to change the settings.

" Press F4 to store the changed setting.

324 BP22_958_1104EN
 Generaltechnicaldescription

Menu structure The passwordfree part of the menu structure is illustrated on the
following pages (example illustration). When the machine is set up,
HOME" is displayed as the start screen for 5seconds.

10

8 7
BP23_033_1202EN 1

BP23_033_1202EN 325
 Generaltechnicaldescription

See
No. 0 Display Function / meaning
page
Displayed for 5seconds once the ignition is
1 Test screen
switched on.
2 HOME Data display 328
Press HOME" in HOME to display the Info"
3 Info 361
menu.
Press Help" to display the help function for
4 Help
whichever menu is currently displayed.
Press F4 in HOME to display the Service"
5 Service 360
menu.
Press F3 in HOME to display the Pump flow
6 Pump flow meter 350
meter" menu.
Press F2 in the Pump flow meter" menu to
7 Fault memory 359
display the Fault memory" menu.
Press F1 in the Pump flow meter" menu
8 Engine diagnosis todisplay the Engine diagnosis" menu 356
(notsupported for all diesel engines)
Press F1 in HOME to display the Pump
9 Pump status 334
status" menu.
Press F2 in HOME to display the Pump
10 Pump settings 341
settings" menu.

326 BP23_033_1202EN
 Generaltechnicaldescription

Test screen This test screen is displayed for 5seconds as soon as the ignition is
switched on.

1 2

BP22_944_1104EN 1

No. 0 Display Function / meaning

1 Version The software version number
2 Test screen Screen displayed when switched on

BP22_944_1104EN 327
 Generaltechnicaldescription

“HOME” menu HOME is displayed after the machine is set up. In this menu,
(start screen) thefunction buttons have the following functions:
− F1 = Pump status" menu
− F2 = Pump settings" menu
− F3 = Pump flow meter" menu
− F4 = Service" menu

Note
Some of the functions illustrated below may not be present on your
machine. The symbol is not lit if a function is not present.

3 4 5

2 7

9
10

11

1 12
13

17 16 15 14
BP22_939_1104EN 2

No. 0 Display Function / meaning

Temperature display, The temperature of the hydraulic fluid is displayed in
1
digital numbers.
Temperature display, The temperature of the hydraulic fluid is displayed
2
analogue graphically.
3 Power input, digital The current power input for the core pump is
displayed in numbers.
4 Power input, analogue The current power input for the core pump is
displayed graphically.
5 Maximum power input, The maximum possible power input for the core pump
digital is displayed in numbers.
→

328 BP22_939_1104EN
 Generaltechnicaldescription

3 4 5

2 7

9
10

11

1 12
13

17 16 15 14
BP22_939_1104EN 4

Continued
No. Display Function / meaning
6 Operating hours meter The machine operating hours are displayed.
7 Stroke counter The total strokes for the machine are displayed.
Concrete pressure, The current concrete pressure is displayed in
8
digital numbers.
The current concrete pressure is displayed graphically.
Concrete pressure,
9 The scale for the graphic display ranges from 0 to the
analogue
maximum possible concrete pressure.
Maximum concrete The set concrete pressure limit is displayed in
10
pressure, digital numbers (see the Pump settings" menu).
11 Output, digital The current output is displayed in numbers.
The current output is displayed graphically. The scale
12 Output, analogue for the graphic display ranges from 0 to the maximum
possible output.
The set output restriction is displayed in numbers (see
13 Maximum output, digital
the Pump settings" menu).
→

BP22_939_1104EN 329
 Generaltechnicaldescription

3 4 5

2 7

9
10

11

1 12
13

17 16 15 14
BP22_939_1104EN 6

Continued
No. Display Function / meaning
Navigation symbol and ser Press F4 to display the Service" menu.
14
vice menu
15 Navigation symbol Press F3 to display the Pump flow meter" menu.
The Local control  0  remote control" switch setting
Navigation symbol and se
16 is displayed.
lected control mode
Press F2 to display the Pump settings" menu.
The pump off", pump on" and reverse pumping"
Navigation symbol and se
17 functions are displayed.
lected pump function
Press F1 to display the Pump status" menu.

330 BP22_939_1104EN
 Generaltechnicaldescription

Special features of the displays in the “HOME” menu

Concrete pressure The concrete pressure value is calculated from the hydraulic pump
display high pressure. When the concrete pump is switched off, the value
8888" is displayed.

Danger
Even though the concrete pump is switched off, there may be a high
concrete pressure in the delivery line (e.g. due to a blockage, for
high−rise pumping). Exercise the necessary care when opening
adelivery line, even if there is no concrete pressure displayed.

Output display The output value is calculated from the stroke time and the geo
metric data of the delivery cylinders at a fill level of 100 %. When
theconcrete pump is switched off, the value 0" is displayed.

BP22_300_0704EN 331
 Generaltechnicaldescription

Symbols for the “HOME” menu

Note
Some of the functions illustrated may not be present on your
machine. This symbol is not lit if a function is not present.

Warning
This symbol lights up yellow if, forexample, a limit value has been
reached.

Fault
This symbol lights up red if a fault has occurred.

Agitator safety cutout

This symbol lights up red if the agitator safety cutout is activated.

EMERGENCY STOP
This symbol lights up red if an EMERGENCY STOP button is
operated.

High-pressure water pump dry running cut-out

This symbol lights up green if the highpressure water pump is
switched on.
This symbol lights up yellow if the water level falls below the level of
the filllevel sensor in the water tank while the highpressure water
pump is switched on.
If the symbol lights up yellow, the highpressure water pump
switches itself off or cannot be switched on. This ensures that the
highpressure water pump cannot be damaged by inadvertently
being allowed to run dry. The dry running cutout can be overridden
using manual emergency operation (see Highpressure water
pump") if the filllevel sensor fails.

332 BP22_954_1209EN
 Generaltechnicaldescription

Hydraulic fluid radiator

This symbol lights up green if the hydraulic fluid radiator is switched
on.

Centralized lubrication system

This symbol lights up green during the lubrication procedure.
The symbol lights up red if a fault is present or a lubricant reservoir is
empty (see description in the section Symbols for the pump settings
menu").

Vacuum return flow filter

This symbol indicates whether the filter element is clogged.
Depending on the warning level, the symbol lights up yellow(low),
orange(medium) or red(high). You can update or reset the display
in the Pump status" menu.
As soon as the symbol lights up red, a bypass valve on the filter
opens and the hydraulic fluid flows into the tank, unfiltered.

Danger
Risk of injury due to faults with the hydraulic fluid circuit. Unfiltered
hydraulic fluid leads to faults with hydraulic components, causing the
machine to move unexpectedly. Ensure that the machine is not run
with unfiltered hydraulic fluid.
If the warning level is red, you must replace the filter element.

Vacuum return flow filter pressure sensor

This symbol indicates whether the pressure sensors or their cable
connections are defective on the vacuum return flow filter.
While this symbol is present, you cannot determine the condition of
the filter element. If this indicator continues to be displayed anyway,
you must have the fault rectified by a Putzmeister service technician.

BP22_954_1209EN 333
 Generaltechnicaldescription

“Pump status” menu In this menu, you can see the various operating states. In this menu,
the function buttons have the following functions:
− F1, F2, F3 = no function
− F4 = switch sensors on or off

1 2 3 4 5

6
BP23_030_1202EN 1

No.0 Display Function / meaning

Moving display of the pumping process in real time
1 Animation
(example illustration).
2 Delivery direction An arrow indicates the direction of delivery.
3 Transfer tube The switchover procedure is displayed graphically.
4 Ammeter The current that controls the swashplate valve is displayed.
Grey: Magnetic switch is OK.

Green: Magnetic switch has switched during the

5 Magnetic switch status
switchover procedure.
Red: Magnetic switch has not switched; the time
monitoring is activated.
Blue: Magnetic switch has not issued any signal.
Magnetic switch or cable defective.
→

334 BP23_030_1202EN

Continued
No. Display
6 High pressure
7 Number of strokes
8 Stroke time
9 Engine speed
Special features of the displays in the “Pump status” menu
Number of strokes and
stroke time
BP23_030_1202EN
Generaltechnicaldescription
1 2 3 4 5
6
BP23_030_1202EN 2
Function / meaning
The hydraulic fluid high pressure is displayed.
The number of strokes per minute is displayed.
The current stroke time is displayed.
The current engine speed is displayed.
The number of strokes and stroke time are not displayed until
thetransfer tube has switched once. When the concrete pump is
switched off, the value0" is displayed.
335
 Generaltechnicaldescription

Symbols of the “Pump status” menu

Note
Some of the functions illustrated may not be present on your
machine. This symbol is not lit if a function is not present.

Engine speed
This symbol flashes if there is no speed of rotation signal (e.g.
engine off, engine speed sensor on engine is defective, concrete
pump is switched on and engine speed is too low for pumping).
You can switch off the sensor (see page340).
− The engine speed must then be adjusted manually.
− The EOC function is switched off.
− The engine speed is not limited.
− The EPS control system calculates the swing angle of the
hydraulic pump using only the maximum engine speed.
− The output is then dependent on the swing angle of the hydraulic
pump and the actual engine speed.

Transfer tube
This symbol flashes if the resolver on the switching shaft is defective.
You can switch off the sensor (see page340).

Magnetic switches
This symbol flashes if one of the magnetic switches on the drive
cylinders is defective.
You can switch off the sensor (see page340).
This activates the emergency controls which allow the pumping
process to continue with restricted functionality.

336 BP23_031_1209EN
 Generaltechnicaldescription

Hydraulic fluid overheating

This symbol flashes if the temperature sensor in the leakage oil line
of the main hydraulic pump measures at least 85°C or is defective.
Then the output is gradually reduced to 20%, and the Warning"
symbol lights up yellow in the HOME" menu.
You can switch off the sensor (see page340).
This reduces the output to 50% and the hydraulic fluid radiator fans
are switched on if the engine is running.

Cause of pump stoppage

This symbol flashes if the pump has been stopped due to a fault.
Inaddition, the cause of the last pump stop is displayed (see the
following table).

Fault code Meaning

1 Agitator safety cutout
2 EMERGENCY STOP
4 Pumpstop" button
8 Engine speed
16 Lower filllevel sensor
32 Pump centralized lubrication system
64 Excess temperature
128 Extern. stop
256 Short circuit
512 Transfer tube sensor
1024 Pressure sensor
2048 Gate valve closed
4096 Stroke counter reached

BP23_031_1209EN 337
 Generaltechnicaldescription

High pressure
This symbol flashes if the pressure sensor on the main hydraulic
pump is defective.
You can switch off the sensor (see page340).
This automatically limits the output to 50%. The pump settings are
automatically set to the factory values.

Output current monitoring

This symbol flashes if there is a fault on a monitored outlet. In addi
tion, the number of the defective outlet is displayed (see the follow
ing table).
It is possible, for instance, that the magnetic coil of a hydraulic valve
is defective. This means that the associated outlet will be automati
cally switched off.
You can then continue to pump in emergency operation.

Outlet Meaning
17 Pump1.1
18 Pump2.1
19 Transfer tube1
20 Transfer tube2

Centralized lubrication system

This symbol lights up red if there is a fault in the pump centralized
lubrication system or boom centralized lubrication system.
Do not operate the machine if the display indicates a fault in the
centralized lubrication system. This leads to increased wear of the
lubricated bearings.

Note
Operating the machine with a defective centralized lubrication sys
tem (which results in wear) leads to a loss of warranty or guarantee
claims.

338 BP23_031_1209EN
 Generaltechnicaldescription

Hopper fill-level sensor

This symbol flashes if the fill level is too low. The concrete pump
stops at the same time, so that no air is sucked in.
You can switch off the sensor (see page340).

Vacuum return flow filter

This symbol lights up red if there is a fault in the filter.
You can switch off the sensor (see page340). Thevacuum return
flow filter warning is then reset for a short time.

Note
This symbol is displayed continuously until the fault is rectified.
Ifthere is a temporary fault on the sensors or the filter element is
lightly contaminated, you can update the symbol on the vacuum
return flow filter from a temperature of 25°C and after several
strokes, as follows:
 Switch off the sensors (the symbol is crossed through).
 Switch on the sensors (the symbol lights up green).
 If the warning lights up after a short time, you must replace the
filter element.

Vacuum return flow filter pressure sensor

This symbol lights up red if the pressure sensors or their cable
connections are defective on the vacuum return flow filter. You can
switch off the sensor (see page340).
While this symbol is displayed, you cannot determine the condition
of the filter element.

BP23_031_1209EN 339
 Generaltechnicaldescription

Emergency operation If a sensor signal that transmits data relevant to the pump control
system fails, emergency operation is possible if you switch off the
sensor. The following displays are possible:

Sensor ... working defective switched off

Symbol normal flashing struck through

Possible causes of sensor signal failure:

− Sensor defective
− Sensor dirty
− Contact with the sensor interrupted

These sensors can be switched off (depending on the machine

model):
− Engine speed
− Angle sensor on the transfer tube switching shaft
− Magnetic switches
− Hydraulic fluid overheating
− High pressure
− Output current monitoring
− Pump centralized lubrication system
− Filllevel sensor
− Vacuum return flow filter

To switch off the sensors using function buttonF4:

− Turn F4 to select a function.
å The symbol is framed in red.
− Then press F4 to activate the selected function.
å The symbol flashes.
− Now turn F4 until the symbol is shown as struck through.
− Press F4 to store the changed setting.
å The symbol is framed in red.

340 BP22_960_1105EN
 Generaltechnicaldescription

“Pump settings” In this menu, you can set the machine’s performance data and
menu operate some of the machine’s functions from the control cabinet.
Inthis menu, the function buttons have the following functions:
− F1, F2, F3 = no function
− F4 = adjust settings, switch functions on or off

Note
Functions indicated with (*) below are optional and depend on the
machine model and its equipment. If the function is not available,
thesymbol is not lit.

The following settings are programmed at the works:

 Concrete pressure = 100%
(restricted to 85bar for piston side drive)
 Output = 100%
 External squeeze valve (*)
 External service operation (*)
 External EOC (*)
 POHOn (*)
 AUTO transfer tube switchover (*)
 Hydraulic fluid radiator AUTO (*)

BP22_941_1104EN 341
 Generaltechnicaldescription

External External" means that the function can be switched on/off at the
radio remote control.

Hydraulic fluid radiator The hydraulic fluid radiator is set to AUTO" at the works. If the
hydraulic fluid reaches the temperatures preset in the hydraulic fluid
radiator control system, the fan(s) are switched on automatically.

If you wish to cool the hydraulic fluid as a precaution, you can switch
on the fan in the menu independently of the temperature (hydraulic
fluid radiator ON).

Changing factory The factory settings of the EOC can be modified at any time by a
settings Putzmeister service technician.

As soon as current is no longer supplied to the control cabinet

(e.g.ignitionoff), the settings are reset to the factory settings.

Switching between rod If the machine is equipped with rod side − piston side feed
side and piston side switching, then this is described on the following pages.
feed

342 BP22_941_1104EN
 Generaltechnicaldescription

Note
Some of the functions illustrated below may not be present on your
machine. The symbol is not lit if a function is not present.

1 2 3 4 5

8 7 6

BP22_942_1205EN 1

No. 0 Display Function / meaning

Concrete pressure limit, The set concrete pressure limit is displayed graphi
1
analogue cally and can be adjusted using the function buttons.
Concrete pressure limit, The set concrete pressure limit is displayed in
2
digital numbers.
Output restriction, The set output restriction is displayed graphically and
3
analogue can be adjusted using the function buttons.
Output restriction,
4 The set output restriction is displayed in numbers.
digital
→

BP22_942_1205EN 343
 Generaltechnicaldescription

1 2 3 4 5

8 7 6

BP22_942_1205EN 2

Continued
No. Display Function / meaning
The date and time are displayed and can be set with
5 Date / time
the function buttons.
In the case of local control operation the setpoint value
6 Output, digital
of output is displayed in numbers.
7 Engine speed The current engine speed is displayed.
8 Stroke counter The current number of strokes is displayed.

344 BP22_942_1205EN
 Generaltechnicaldescription

Symbols for the “Pump settings” menu

Note
Some of the functions illustrated below may not be present on your
machine. The symbol is not lit if a function is not present.

If a function can be switched to External" (symbol plus arrow), then

the function can be switched on/off by radio remote control.

Centralized lubrication system

The symbol lights up green during the lubrication procedure.
You can start a manual lubrication procedure by using the F4
function button to select and press the symbol.
If a fault is present or if a lubricant reservoir is empty, the symbol
lights up red and is also displayed in the HOME" menu.
The Centralized lubrication system" symbols clarify whether the fault
is in the boom centralized lubrication system or the pump centralized
lubrication system.

Note
The red Centralized lubrication system" symbol is displayed per
manently until the fault is rectified. In Menu7" of the EGDRC on
theradio remote control, the Centralized lubrication system fault"
symbol is also displayed.
Rectify the fault in the centralized lubrication system as follows:
 Fill the empty lubricant reservoir.
 Start a manual lubrication procedure.
 If the red Centralized lubrication system" symbol lights up again
after a short time, you must start a manual lubrication procedure
again.
The red Centralized lubrication system" symbol in the HOME"
menu goes out along with the Centralized lubrication system fault"
symbol on the radio remote control. If there is no fault, the Central
ized lubrication system" symbol lights up green.

BP22_956_1208EN 345
 Generaltechnicaldescription

Squeeze valve (optional)

The function can be switched on/off (I/0) or switched to External"
using the function buttons.
The squeeze valve closes off the delivery line when the pump stops.
If the squeeze valve is switched on, the delivery line will be sealed
off as soon as you switch the pump off at the remote control. The
squeeze valve opens as soon as you restart the pump at the remote
control.

Service operation (compressor)

The function can be switched on/off (I/0) or switched to External"
using the function buttons.
If you preselect the compressor, you can use the remote control to
switch on the compressor rather than the pump.

Note
As soon as the compressor is switched on, the agitator control block
is no longer supplied with hydraulic fluid, i.e.the agitator and the
water pump will not run.

346 BP22_956_1208EN
 Generaltechnicaldescription

EOC (Ergonic Output Control), (optional)

The function can be switched on/off (I/0) or switched to External"
using the function buttons.

Stroke counter
The current number of strokes is displayed next to the symbol.
You can reset the stroke counter to 0" by using the F4 function
button to select and press the symbol.

Push Over (optional)

The function can be switched on/off (I/0) or switched to External"
using the function buttons.
When you switch on the Push Over function, the delivery piston starts
up more quickly after the switch over. This shortens the interruptions
in delivery and there is only a minimal break in the output flow rate.
When you switch off the Push Over function, the delivery piston
accelerates evenly at the start of the stroke. This pushes the
concrete more gently. The interruptions in delivery at the switch
overare marginally longer.

Hydraulic fluid radiator (optional)

The operation mode for the hydraulic fluid radiator can be selected
using the function buttons (AUTO/ON).

BP22_956_1208EN 347
 Generaltechnicaldescription

Centralized lubrication system

Note
The pump centralized lubrication system and the boom centralized
lubrication system are two completely independent systems, that is
two pumps, two lubricant reservoirs, two controllers, etc.

Technical data Rated voltage (V DC) 12 / 24

Operating voltage (V DC) 9 to 30

Max. power consumption

(A) 6,5
for the engine at 12 V

Max. power consumption

(A) 3
for the engine at 24 V

Lamp current (A) 2

Permissible operating
(°C) −40 to +70
temperature

secure against polarity

Supply voltage inlets
reversal

secure against polarity

Supply voltage outlets reversal/shortcircuit
protected

Degree of protection fitted

IP 6 K 9 K DIN 40050 T9
in the pump casing

348 BP23_103_1208EN
 Generaltechnicaldescription

Programming Various settings are programmed into the centralized lubrication

system in the works. These settings regulate the lubrication intervals
and the lubrication time. Have the default settings modified by the
After Sales Department if either the lubrication intervals or the lu
brication times do not meet your needs. The following settings are
stored:

Interval time The interval time is the time between two lubrication procedures.
Theinterval time only runs down when the ignition is switched on.
The interval times are retained during interruptions. The new times
are added on restarting.

Working time The working time is the time for which the centralized lubrication
pump operates for one lubrication procedure. The working time is
the period during which a response must be received from the piston
detectors.

Monitoring time The monitoring time starts when the centralized lubrication pump
isswitched on. The monitoring time is the time taken for the piston
detector to respond.

BP23_103_1208EN 349
 Generaltechnicaldescription

“Pump flow meter” In this menu, you can read off outputs in order to record job volumes
menu on the construction site, service intervals or the total output, for in
stance. In this menu, the function buttons have the following func
tions:
− F1 = Engine diagnosis" menu
− F2 = Fault memory" menu
− F3 = passwordprotected service area
− F4 = adjust settings

1
4 7

2 5 7

3 6 8

13 12 11 10
BP22_943_1203EN 1

No. 0 Display Function / meaning

Setpoint value for the out
1 The specified output is displayed.
put
2 Actual value for the output The output achieved is displayed.
Remaining value for the
3 The remaining output is displayed.
output
Setpoint value for the The specified number of strokes based on the output
4
number of strokes is displayed.
Actual value for the number
5 The number of strokes achieved is displayed.
of strokes
Remaining value for the
6 The remaining number of strokes is displayed.
number of strokes
→

350 BP22_943_1203EN
 Generaltechnicaldescription

1
4 7

2 5 7

3 6 8

13 12 11 10
BP22_943_1203EN 2

Continued
No. Display Function / meaning
Outputs for 2individual periods are displayed (the va
7 Output display
lues can be reset).
The total output is displayed (the value cannot be
8 Output display, total
reset).
The specified fill level is displayed (adjustable to be
9 Fill level
tween 70% and 100%).
10 passwordprotected service area
11 Navigation symbol Press F2 to display the Fault memory" menu.
12 Navigation symbol Press F1 to display the Engine diagnosis" menu.
13 Switch The pump flow meter can be switched on/off(I/0).

BP22_943_1203EN 351
 Generaltechnicaldescription

Method of operation of the pump flow meter

Output The output is calculated from the geometric data of the delivery
cylinders at the fill level specified by you.

Switching the pump You can switch the pump flow meter on/off. When the pump flow
flow meter on/off meter is switched on, the concrete pump stops as soon as the
specified output is achieved. If you then switch the concrete pump
off and on again, the pump flow meter starts to count again from the
specified setpoint value.

Note
The pump flow meter is switched off in the works. As soon as current
is no longer supplied to the control cabinet (e.g.ignitionoff), the
settings are reset to the factory settings.

If no setpoint value is specified for the output, the concrete pump

runs without parameters. The output displays still run. The values
arecalculated using the set fill level.

352 BP22_957_1104EN
 Generaltechnicaldescription

Setpoint value for the You can specify a value for the output at which the concrete pump
output should switch off. The accuracy of the volumes indicated is depen
dent on the current fill level of the delivery cylinders. The more
accurately you enter the fill level in percent, the more accurate
thedisplay.

Specifying a setpoint Enter the setpoint value for the output as follows:
value for the output
" Turn F4 to select the setpoint value.
å The setpoint value is displayed in inverse video.

" Then press F4 to activate the setpoint value.

å The first digit of the setpoint value flashes.

" Now turn F4 to change the first digit.

" Press F4 to store the changed setting of the first digit.

å The second digit of the setpoint value flashes.

" Go through all the digits of the setpoint value in sequence.

Note
If you change the setpoint value, the actual value and the remaining
value will be reset to0".

Actual / remaining Once the transfer tube has switched over for the first time, the
value for the output actualvalue starts to count the output achieved. The remaining
valueshows the output still to be achieved at the same time.

Note
As soon as the setpoint value is reached, the actual value and the
remaining value are reset to0".

BP22_957_1104EN 353
 Generaltechnicaldescription

Resetting the output Reset the Output displays1 and2" to zero as follows.
display
" Turn F4 to select the arrow next to the value.
å The arrow is displayed in inverse video.

" Then press F4 to activate the value.

å The arrow flashes.

" Now turn F4 to reset the value to zero.

" Press F4 to store the changed setting.

å The arrow is displayed in inverse video again.

Setpoint, actual, The displayed numbers of strokes are calculated from the specified
remaining value for setpoint value for the output and the geometric data for the delivery
number of strokes cylinder. The values cannot be adjusted manually.

354 BP22_957_1104EN
 Generaltechnicaldescription

Entering the fill level of Enter the fill level of the delivery cylinders as described below:
the delivery cylinders
Note
The usual fill level of the delivery cylinders is between 70% and
90% (average value: 85%).

Use the formula to calculate the fill level for your own concrete mix
formula:

Amount of concrete in the truck mixer

Fill level =
Number of strokes x (Volume of one delivery cylinder)

The specified fill level remains stored even when the ignition is
switched off.

Calculation Amount of concrete in the truck mixer 8000dm3

example
Number of strokes
(count the number of strokes, until you have 160
pumped the 8000dm3 of concrete.)

Volume of one delivery cylinder

(when D=230mm and L=1400mm)
58.16dm3
* D = diameter
* L = length

å Fill level 85%

" Turn F4 to select the fill level.

å The arrow is displayed in inverse video.

" Then press F4 to activate the fill level.

å The arrow flashes.

" Now turn F4 to change the fill level.

" Press F4 to store the changed setting.

å The arrow is displayed in inverse video again.

BP22_957_1104EN 355
 Generaltechnicaldescription

“Engine diagnosis” In this menu, you can see the various operating states. In this menu,
menu the function buttons have the following functions:
− F1, F2, F3, F4 = no function

Note
The bar charts and fault messages are only active for engines with
an electronic engine governor (EMR).

1 2

BP22_964_1105EN 2

No. 0 Display Function / meaning

1 Operating hours, digital The engine operating hours are displayed in numbers.
2 Engine speed, analogue The current engine speed is displayed graphically.
→

356 BP22_964_1105EN
 Generaltechnicaldescription

1 2

BP22_964_1105EN 4

Continued
No. Display Function / meaning
Possible faults in the electronic engine governor (EMR)
3 Fault messages
are displayed.
Cooling water temperature, The cooling water temperature is displayed in
digital numbers.
4
Cooling water temperature,
The cooling water temperature is displayed graphically.
analogue
Engine oil pressure,
The engine oil pressure is displayed in numbers.
digital
5
Engine oil pressure,
The engine oil pressure is displayed graphically.
analogue
Battery voltage / battery
The battery voltage / battery power are displayed in
6 power, digital and ana
numbers and illustrated graphically.
logue
Fuel consumption, digital The current fuel consumption is displayed in numbers.
7
Fuel gauge, analogue The fill level of the fuel tank is illustrated graphically.

BP22_964_1105EN 357
 Generaltechnicaldescription

Special features of the “Engine diagnosis” menu

EMR fault messages If there are faults in the electronic engine governor (EMR), the fault
messages are shown using a numerical code in the display. You can
use the numerical code to identify the fault in the system description
of the electronic engine governor.
− The number before the decimal point corresponds to the SPN
(Suspected Parameter Number)
− The number after the decimal point corresponds to the FMI (Fail
ure Mode Identifier).

358 BP22_964_1105EN
 Generaltechnicaldescription

“Fault memory” menu In this menu, the fault codes for the last 10 faults are displayed. In
this menu, the function buttons have no functions.

1 2 3 4

BP22_965_1105EN 1

No. 0 Display Function / meaning

1 Fault The fault code is displayed.
2 Date The date of the fault events are displayed.
3 Start The start of the fault events are displayed.
4 End The end of the fault events are displayed.

BP22_965_1105EN 359
 Generaltechnicaldescription

“Service” menu From this menu you can navigate to the passwordprotected service
area of the EGD. In this menu, the function buttons have the following
functions:
− F1, F2, F3 = passwordprotected service area
− F4 = adjust settings

BP22_947_1104EN 1

No. 0 Display Function / meaning

1 Input field The password for the service area can be entered.

Caution
Control system parameters can be set in the service area of the
EGD. If parameters are incorrectly set, the control system may mal
function. Access to the service area is therefore passwordprotected
and only granted to Putzmeister service engineers.

360 BP22_947_1104EN
 Generaltechnicaldescription

“Info” menu This menu lists the software versions of the control systems. In this
menu, the function buttons have no functions.

1 2
BP22_946_1104EN 1

No. 0 Display Function / meaning

The software versions of the control systems are
1 Software versions
displayed.
2 Machine number The machine number is displayed.

BP22_946_1104EN 361
 Generaltechnicaldescription

3.6.4 Ergonic Output Ergonic Output Control (EOC) is electronically controlled output
Control regulation which adapts the engine speed to the delivery rate
selected. You can switch the EOC function on or off at the Ergonic
Graphic Display (EGD). It is recommended that you switch off EOC
in arduous pumping conditions (e.g.highdensity concrete).

Note
As soon as no current is supplied to the control cabinet (e.g.ignition
off, power takeoff off), the settings are reset to the factory settings.

When the EOC function is switched off, the maximum engine speed
specified in the works is activated.

“Pump settings”
menu 1

BP22_948_1104EN 1

No. 0 Display Function / meaning

Ergonic Output Control The EOC function can be switched on/off (I/0) using F4
1
(EOC) or can be assigned to the radio remote control.

362 BP22_948_1104EN
 Generaltechnicaldescription

Special features of Ergonic Output Control

Ergonic Output Control In the Pump settings menu you can switch the EOC control system
on or off, or assign this function to the radio remote control.

Note
You can only switch EOC on or off at the radio remote control if you
set the EOC to the radio remote control" position.

Engaging the power After switching on the PTO, the engine speed stays at idling speed.
takeoff

Hydraulic fluid If the hydraulic fluid temperature is less than 25°C, the output is
temperature reduced to a maximum of 50% in EOC operation. If the hydraulic
fluid temperature exceeds 25°C, the output is regulated to the value
that is set at the remote control potentiometer.

Boom or support leg The engine speed is increased to 12001350rpm, depending on

function the vehicle, as soon as you operate a boom or support leg function
with the concrete pump switched off.

BP22_948_1104EN 363
 Generaltechnicaldescription

Pump On As soon as you switch on the concrete pump, the engine speed is
increased to a level appropriate for the delivery rate set on the out
put regulation rotary controller, but to no less than 1350rpm.

Output Engine speed

0% Idling speed (after 10seconds)
075% 1350rpm
>75% 1350rpm−maximum engine speed

If the output is set to more than 75%, the engine speed is increased
until the computed engine speed is reached (but to no more than the
maximum engine speed).

If the output is set to less than 75%, the engine speed is held at
1350rpm. The actuating pressure for the hydraulic pump is then
modified automatically.

Note
Depending on the truck model, the engine speed can be adjusted to
a precise value of +/−50rpm.

364 BP22_948_1104EN
 Generaltechnicaldescription

Pump Off, The engine speed is reduced to idling speed after 10seconds
or no boom movement (works setting), when you
− reduce the output to 0%, or
− switch off the concrete pump, or
− cease to operate the boom with the concrete pump off.
Should you switch the concrete pump back on or operate a boom
function inside this 10second delay, the engine speed is maintained.

Water pump and other You must increase the engine speed manually in order to operate the
auxiliary units water pump (or the other auxiliary units). As soon as you switch off
the water pump, the engine speed is reduced to 850rpm after
10seconds (works setting). If you should switch the water pump
back on within these 10seconds, the engine speed is maintained.

Adjusting the engine If you change the engine speed manually using the remote control
speed manually while the concrete pump is switched on, this manually set engine
speed is maintained until you:
− adjust the output at the rotary controller again,
− disengage the power takeoff,
− switch off the ignition.

BP22_948_1104EN 365
 Generaltechnicaldescription

3.6.5 Control panel in the The control panel is located in or near the steps. The truck mixer
steps driver can control the most important functions of the pump from
thecontrol panel. In addition, it provides an opportunity for local
operation of the machine. Some of the control and operating
elements illustrated below may not be present on your machine.
Thehole will be filled with a blanking plug if a control or operating
element is omitted.

1 2 3

9
4

8 5

7 6
BP22_926_1102EN 1

Operating/
No. 0 Meaning/function
control element
1 Toggle switch Increase − Reduce engine speed
2 Toggle switch Forward pumping − 0 − Reverse pumping
Agitator On − agitation direction away from the delivery cylinder
3 Toggle switch Agitator Off
Agitator On − agitation direction towards the delivery cylinder
Flushing water pump On
4 Toggle switch Zero position
Highpressure water pump On
5 Toggle switch Acknowledge the agitator safety cutout
Horn + deactivate EMERGENCY STOP /
6 Toggle switch
Pump Off
7 Toggle switch Vibrator On − Off
8 Toggle switch Working light On − Off
9 Momentarycontact EMERGENCY STOP
switch

366 BP22_926_1102EN
 Generaltechnicaldescription

Special features of the control panel

Restarting the pump If you have pressed the EMERGENCY STOP button, you may only
after EMERGENCY start the pump up again as described below:
STOP − Unlock the EMERGENCY STOP button by turning it,
− press the Horn + deactivate EMERGENCY STOP" toggle switch,
− activate the Acknowledge the agitator safety cutout" toggle
switch,
− switch the pump off and then on again using the Forward pump
ing − 0 − Reverse pumping" toggle switch.

Locally latched toggle To use a locally latched toggle switch, you must first pull it out and
switches then push it towards the symbol.

Forward pumping − 0 − The function of the Forward pumping − 0 − Reverse pumping"

Reverse pumping toggle switch depends on the switch position of the LocalRemote
switch on the control cabinet.
− When the toggle switch is set to Local", it has the functions given
above.
− When the switch is set to Remote", it is only possible to switch the
pump off using the Pump off" toggle switch. The Forward pump
ing − 0 − Reverse pumping" toggle switch then has no effect.

Water pumps The valves for the agitator control block are actuated such that the
water pump and the agitator do not operate simultaneously.

Acknowledge the If the agitator safety cutout is triggered, it must be acknowledged

agitator safety cutout with the toggle switch so that the agitator starts running again and
the accumulator refills.

BP22_926_1102EN 367
 Generaltechnicaldescription

3.6.6 Cable remote control The standard cable remote control for this machine is illustrated
below.

9
2

10
1 3
8

7
4

6 5

BP21_694_0904EN 1

Operating/ Belongs
No. 0 Meaning/Function
control element with no.:
1 Joystick Boom control
2 Rotary controller Setting the boom speed
3 Toggle switch Forward pumping − 0 − Reverse pumping
Horn + deactivate EMERGENCY STOP /
4 Toggle switch
Change−over
5 Rotary controller Increase − Reduce output
6 Toggle switch Engine On − Off
7 Toggle switch Increase − Reduce engine speed
8 Locally latched toggle switch Boom functions − 0 − Support leg control
9 Red indicator lamp Fault (e.g. EMERGENCY STOP operated)
10 Momentary−contact switch EMERGENCY STOP

368 BP21_694_0904EN
 Generaltechnicaldescription

Special features of the cable remote control

Restarting the pump The red Fault" indicator lamp lights up when the EMERGENCY
after EMERGENCY STOP button is pressed. You may only start the pump up again as
STOP described below:
− Unlock the EMERGENCY STOP button by turning it,
− press the Horn + deactivate EMERGENCY STOP" toggle switch,
− switch the pump off and then on again using the Forward
pumping− 0 − Reverse pumping" toggle switch.

Locally latched To use a locally latched toggle switch, you must first pull it out and
toggleswitches then push it towards the symbol.

BP21_694_0904EN 369
 Generaltechnicaldescription

3.6.7 Radio remote control The transmitter for a proportional radio remote control is described
below.

Radio remote control transmitter

ÁÁÁ
1 2 3 4 5 6 7

ÁÁÁ
ÁÁÁ

ÁÁ
ÁÁ
13 12 11 10 9 8

BP23_111_1209EN 1

Operating/ Belongs
No. 0 Meaning/function
control element with no.:
1 Joystick Boom control
Toggle switch,
2 Boom functions − 0 − Support leg control
locallylatched
Momentarycontact
3 STOP function
switch
Flashing green: radio remote control in
service
4 Indicator lamp 5
Off: no contact with receiver
Flashing red: battery flat
5 Toggle switch Radio remote control On − Off 4
6 Toggle switch Forward pumping − 0 − Reverse pumping
7 Joystick Boom control
Momentarycontact
8 Increase − Reduce engine speed
switch
→

370 BP23_111_1209EN
 Generaltechnicaldescription

ÁÁÁ
1 2 3 4 5 6 7

ÁÁÁ
ÁÁÁ

ÁÁ
ÁÁ
13 12 11 10 9 8

BP23_111_1209EN 2

Continued
Operating/ Belongs
No. Meaning/function
control element with no.:
Horn + deactivate EMERGENCY STOP /
9 Toggle switch
Changeover
10 Rotary controller Increase − Reduce output
Menudriven displays and adjustable
11 Display
functions
12 Rotary pushbutton Operating the display
Momentarycontact
13 Engine On − Off
switch

BP23_111_1209EN 371
 Generaltechnicaldescription

Receiver

4
BP23_111_1209EN 3

Operating/ Belongs
No. 0 Meaning/function
control element with no.:
1 Female connector Aerial connection
2 Indicator lamps Operating states display
3 Aerial with base Control signal reception
4 Female connector Connection to the control cabinet

372 BP23_111_1209EN
 Generaltechnicaldescription

Special features of the radio remote control

Caution
After using the "teachin" function on the transmitter or receiver,
youcan only switch off the power supply to the receiver once the
rundown time of approx. 20seconds has elapsed.
During this rundown time, "teachin" parameters are transmitted to
the receiver and saved.
If you interrupt this rundown time, this will lead to an abnormal
system end in the radio software and damage to the radio
installation.

STOP button Putzmeister radio remote controls include a STOPbutton which

hasthe same function as the EMERGENCY STOP buttons on the
machine. This is a requirement of European standard EN602041.

Starting up the pump You may only start the pump up again as described below if you
after STOP have pressed the STOPbutton:
− Unlock the STOP button by turning it,
− switch the radio remote control off and back on again,
− press the "Horn + deactivate EMERGENCY STOP" toggle switch,
− switch the pump off and then on again using the "Forward pump
ing − 0 − Reverse pumping" toggle switch.

BP23_111_1209EN 373
 Generaltechnicaldescription

Frequency change 12frequencies on the frequency band have been assigned to this
radio remote control. As soon as you switch the transmitter off or
press the STOP button on the transmitter, the link between the
transmitter and receiver is disconnected. The radio remote control
automatically advances to the next frequency when you switch the
transmitter back on.

Additional aerials You must maintain a minimum clearance of 1m between the radio
remote control and any additional aerials (e.g.radio, telephone)
which you fit, otherwise these may interfere with the radio remote
control.

Locally latched toggle To operate a locally latched toggle switch, you must first pull it out
switches and then push it towards the symbol.

Joystick The two joysticks can be used to control the individual boom
functions. You can control some of the boom functions for 4 and
5arm booms by rotating the joysticks.

374 BP23_111_1209EN
 Generaltechnicaldescription

3.6.8 Ergonic Graphic The Ergonic Graphic Display−Remote Control (EGD−RC) is a

Display – Remote graphic display in the radio remote control. The EGD−RC allows you
Control to determine the operating state of the machine. You can use the
EGD−RC operating elements to navigate between the menus and to
make settings.

Note
Depending on the equipment fitted to your machine, some of the
functions illustrated may not be present.

EGD–RC and

ÁÁ
operating elements

ÁÁ
ÁÁ
ÁÁ ÁÁ
ÁÁ
1 2

BP21_714_0704EN 1

Operating/
No. 0 Function / meaning
control element
1 Rotary push−button Function button for selecting and setting
Menu−driven displays and adjustable functions are
2 EGD−RC
shown in the EGD−RC.

BP21_714_0704EN 375
 Generaltechnicaldescription

Using the menus

Display lighting The display lighting comes on as soon as you turn the function
button. The lighting goes out again after approximately 10seconds.
You must select the lamp symbol in the status line in the top line of
the display using the function button and then press it to light the
display permanently.
å The symbol is displayed without a line through it. The
display lighting is switched on permanently.

Note
Additional power is required to light the display, which causes the
battery in the remote control unit to drain more quickly.

Change menu The upper line of the display includes a menu line showing numbers.
Each number is assigned a fixed menu. If certain equipment is not
present on your machine, the associated menu does not exist and
the associated number is not visible.

The number of the menu currently displayed is shown in inverse

video. Turn the function button to change to a different menu. The
number of the menu selected flashes. Change to the menu selected
by then pressing the function button.

Displayed units The pressure, temperature and volume units can be switched at
thecontrol cabinet (bar/Celsius/m3 or psi/Fahrenheit/yd3). In the
EGD−RC, the same units which have been selected at the control
cabinet are displayed.

376 BP21_714_0704EN
 Generaltechnicaldescription

Selecting functions You can select functions in the menus using the programmed
switches as follows:

" Turn the function button to select a function.

å The function flashes in inverse video.

" Then press the function button to activate the selected

function.
å The function is displayed in inverse video.

" Now turn the function button to change the settings.

" Press the function button to store the changed setting.

å The function flashes in inverse video again.

BP22_353_0803EN 377
 Generaltechnicaldescription

Menu structure The maximum possible menu structure is shown on the following
pages. If certain equipment is not present on your machine, the
associated menu does not exist and the associated number is not
visible in the status line. When the transmitter is started up, the test
screen appears first, then the EGDRC switches to menu7 and
displays EMERGENCY STOP".

BP22_931_1103EN 1

See
Display Function / meaning
page
Test screen Screen after switching on / radio link fault 327
Menu1 Operating elements 382
Menu2 EPS status / EBC status 385
Displays concrete pressure and concrete pressure
Menu3 389
limit
Menu4 (without EBC) Locks boom arms / stores or selects boom speed 391
Menu4 (with EBC) Displays and stores limits 396
Menu5 Not assigned
Menu6 EPS limits 3100
Menu7 Faults 3101
Menu8 Pump flow meter 3106

378 BP22_931_1103EN
 Generaltechnicaldescription

Test screen This test screen appears

− for a few seconds as soon as you switch on the transmitter
− permanently when the connection between the transmitter and
thereceiver is interrupted.

2
BP21_717_0703EN 1

No. 0 Display Function / meaning

1 Test screen Screen after switching on/connection interrupted
2 Version The software version number

BP21_717_0703EN 379
 Generaltechnicaldescription

Standard displays Menus1,2 and 3 contain displays for a variety of different functions.

1 2 3

6 4

7 5

8 9

10
BP22_876_1006EN 1

No. 0 Display Function / meaning

1 Menu line
2 Pump function
3 Display lighting
4 Temperature display, digital
5 Output, digital
6 Engine speed, digital
7 Concrete pressure, digital
8 Display (Menu1+3 only)
9 Display (Menu1+3 only)
10 Switch
Shows the number of the menu currently displayed in
inverse video and the menu selected is shown flash
ing.
The symbol shows that the concrete pump is pumping
forwards.
Lamp with a line through it: lighting only switched on
during operation
Lamp: lighting permanently switched on
The temperature of the hydraulic fluid is displayed in
numbers.
The current output is displayed in numbers.
The current engine speed is displayed in numbers.
The current concrete pressure is displayed in
numbers.
Displays the field strength.
Displays the residual charge in the battery.
See Menu 1"

380 BP22_876_1006EN
 Generaltechnicaldescription

Special features of the standard displays

Concrete pressure The concrete pressure value is calculated from the hydraulic pump
display high pressure. When the concrete pump is switched off, the value
8888" is displayed. If a concrete pressure limit is set at the control
cabinet, the value is displayed here in inverse video.

Danger
Even though the concrete pump is switched off, there may be a high
concrete pressure in the delivery line (e.g. due to a blockage or
when high−rise pumping). Exercise the necessary care when open
ing a delivery line, even if there is no concrete pressure displayed.

Output display The output value is calculated from the stroke time and the geomet
ric data of the delivery cylinders at a fill level of 100 %. When the
concrete pump is switched off, the value 0" is displayed. If an out
put limit is set at the control cabinet, the value is displayed here in
inverse video.

BP22_876_1006EN 381
 Generaltechnicaldescription

Menu 1 The switches for those functions which can be switched on and off
are found in Menu 1.

2
BP22_877_1006EN 1

No. 0 Display Function / meaning

1 Indicators See Standard displays"
Operating elements for the concrete pump and attach
2 Switch
ments

382 BP22_877_1006EN
 AllgemeinetechnischeBeschreibung

Symbols for Menu 1

Note
Some of the functions illustrated below may not be present on your
machine. The symbol is not lit if a function is not present.

EOC (Ergonic Output Control)

You can switch the EOC function on/off(I/0) using the rotary push
button.

Boom speed preselection

You can select the boom speed as follows:
− Fast = 100% works setting
− Normal = 50% works setting
− Userdefined boom speeds

Store function
This symbol shows the Store" switch.

In EBC mode:
Storing and deleting
You can store and delete settings (e.g. limits).

Without EBC operation:

Programming user-defined boom speed (see page 3 — 93)
You can program your own speed for each of the boom functions.
− Use the function shown on the left to program the maximum move
ment speed.
− Use the function shown on the right to program the minimum
movement speed.

BP22_878_1007EN 383
 AllgemeinetechnischeBeschreibung

Agitator
You can switch the agitator on/off(I/0) using the rotary pushbutton.
− Agitator On − agitation direction away from the delivery cylinder
− Agitator Off
− Agitator On − agitation direction towards the delivery cylinder

Vibrator
You can switch the vibrator on/off(I/0) using the rotary pushbutton.
The vibrator only runs when the concrete pump is switched on.

Squeeze valve (optional)

You can switch the squeeze valve on/off(I/0) using the rotary push
button.
The squeeze valve closes off the delivery line when the pump stops.
If the squeeze valve is switched on, the delivery line will be sealed
off as soon as you switch the pump off at the remote control. The
squeeze valve opens as soon as you restart the pump at the remote
control.

Push Over (optional)

You can switch the Push Over function on/off(I/0) using the rotary
pushbutton.
When you switch on the Push Over function, the delivery piston starts
up quicker after the switch over. This shortens the interruptions in
delivery and there is only a minimal break in the output flow rate.
When you switch off the Push Over function, the delivery piston ac
celerates evenly at the start of the stroke. This pushes the concrete
more gently. The interruptions in delivery at the switch over are mar
ginally longer.

Pumping operation – Service operation (optional)

With this function, you can use the rotary pushbutton to toggle be
tween the concrete pump and the compressor. If you have switched
the software switch to the compressorON" position, the compressor
and not the concrete pump will switch on in response to the toggle
switch on the remote control.

384 BP22_878_1007EN
 Generaltechnicaldescription

Menu 2 In Menu 2 you can see the various machine operating states.

BP21_718_0703EN 1

No. 0 Display Function / meaning

1 Indicators See Standard displays"
2 EPS status line The operating state of the pump control system is displayed.
3 EBC status line The operating state of the boom control is displayed.

Note
Symbols are only displayed in the EBC status line if the machine has
an EBC control and this is switched on.

BP21_718_0703EN 385
 Generaltechnicaldescription

Symbols for Menu 2

EPS status line In normal conditions, the EPS status line is blank. The associated
symbol is only displayed if there is a message. The symbols are
notdisplayed in a fixed position; they are filled in from left to right in
thesequence in which they appear. The following symbols can be
displayed here:

Hydraulic fluid radiator

The symbol shows that the hydraulic fluid radiator is switched on.

Agitator safety cutout

The symbol shows that the agitator safety cutout is activated
(grilleopened).

EOC (Ergonic Output Control)

The symbol shows whether the EOC function is switched on or off.

Squeeze valve (optional)

The symbol shows whether the squeeze valve function is switched
on or off.

Hopper fill-level sensor (optional)

The symbol shows that the hopper is full.

Vacuum return flow filter

Symbol displays a fault in the filter.
In older software versions, the message 143" is displayed.

386 BP23_032_1202EN
 Generaltechnicaldescription

EBC status line In normal conditions, the EBC status line is blank. The associated
symbol is only displayed if you have stored a limit or preferred posi
tion. The symbols are not displayed in a fixed position; they are filled
in from left to right in the sequence in which they appear. The follow
ing symbols can be displayed here:

Note
When the boom reaches a limit (upper, lower, slewing gear) in EBC
operation, the associated symbol flashes.

If the symbol is crossed out, it means that the EBC selector switch is
not in the Move end hose" switch position. Programmed limits are
not being monitored.

Upper limit
An upper limit is programmed. The measurement is from the height
of the slewing head to the boom tip. Arms cannot move above this
limit in the Move end hose" EBC operating mode (EBC selector
switch in switch position2).

Lower limit
A lower limit is programmed. The measurement is from the height of
the slewing head to the boom tip. Arms cannot move below this limit
in the Move end hose" EBC operating mode (EBC selector switch in
switch position2).

Slewing gear limit to the left

A left limit (to the left of the longitudinal axis of the truck) is pro
grammed. The boom cannot be moved beyond this limit in the
Move end hose" EBC operating mode (EBC selector switch in
switch position2).

Slewing gear limit to the right

A right limit (to the right of the longitudinal axis of the truck) is pro
grammed. The boom cannot be moved beyond this limit in the
Move end hose" EBC operating mode (EBC selector switch in
switch position2).

BP22_348_0803EN 387
 Generaltechnicaldescription

Slewing gear limit to the left and right

A left and right limit is programmed. The boom cannot be moved
beyond these limits in the Move end hose" EBC operating mode
(EBC selector switch in switch position2).

Preferred position for arm 1

A preferred position is programmed for arm1. In the Move end
hose" EBC operating mode (EBC selector switch in switch posi
tion2), arm 1 is no longer moved.

Preferred position for last arm

A preferred position is programmed for the last arm. In the Move
end hose" EBC operating mode (EBC selector switch in switch
position2), the last arm is no longer moved.

Preferred position for arm 1 and last arm

For the last arm and arm 1, a preferred position is programmed for
each. In the Move end hose" EBC operating mode (EBC selector
switch in switch position2), the last arm and arm 1 are no longer
moved.

Preferred position for arm 1 and arm 2

For arm 1 and arm 2, a preferred position is programmed for each.
In the Move end hose" EBC operating mode (EBC selector switch
inswitch position2), arm 1 and arm 2 are no longer moved.

388 BP22_348_0803EN
 Generaltechnicaldescription

Menu 3 Menu 3 gives the concrete pressure limit and the current concrete
pressure.

2 3

BP21_721_0703EN 1

No. 0 Display Function / meaning

1 Indicators See Standard displays"
The current concrete pressure is displayed graphically.
Concrete pressure,
2 The scale for the graphic display ranges from 0 to the
analogue
maximum possible concrete pressure.
The set concrete pressure limit is displayed in numbers
Maximum concrete
3 (see the Pump settings" menu in the Ergonic Graphic
pressure, digital
Display).

BP21_721_0703EN 389
 Generaltechnicaldescription

Special features of the display for Menu 3

Concrete pressure The concrete pressure value is calculated from the hydraulic pump
display high pressure. When the concrete pump is switched off, the value
8888" is displayed.

Danger
Even though the concrete pump is switched off, there may be a high
concrete pressure in the delivery line (e.g. due to a blockage or when
high−rise pumping). Exercise the necessary care when opening a
delivery line, even if there is no concrete pressure displayed.

390 BP21_721_0703EN
 Generaltechnicaldescription

Menu 4 (without EBC) In Menu4 (without EBC) you can lock the boom arm, and program
and select the boom speeds.

3 4

BP21_720_0703EN 1

No. 0 Display Function / meaning

Shows the number of the menu currently displayed in inverse
1 Menu line
video and the menu selected is shown flashing.
2 Switch Locks the boom arm
3 Switch Selects the boom speed
4 Switch Programs user−defined boom speed

BP21_720_0703EN 391
 Generaltechnicaldescription

Symbols for Menu 4 (without EBC)

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

Inhibiting slewing gear transmission/

locking the slewing cylinder
You can inhibit the slewing movement of the arm assembly
(symbolwith padlock) or unlock it.

Locking the boom arm (example A–Arm = Arm 1)

You can lock each of the boom arms (symbol with padlock)
orunlockthem.

Boom speed preselection

You can select the boom speed as follows:
− Fast = 100% works setting
− Normal = 50% works setting
− User−defined boom speeds

Store function
This symbol shows the Store" switch.

Without EBC operation:

Programming user–defined boom speed (see page 3 — 93)
You can program your own speed for each of the boom functions.
− Use the function shown on the left to program the maximum
movement speed.
− Use the function shown on the right to program the minimum
movement speed.

392 BP22_334_0703EN
 Generaltechnicaldescription

Programming your own boom speed

Note
Each boom movement must be programmed individually.

Programming a maximum speed

BP22_337_0703EN 1

" Set the Preselect boom speed" switch to User−defined

boomspeed".

" Select the store function.

" Press the function button to activate the store function.

" Turn the function button to select the Maximum boom speed"
symbol.

" Hold the function button pressed.

" Use the joystick to control the desired boom movement at the
same speed that is to become the maximum movement speed
for full joystick deflection.

" Release the function button first and then the joystick.

BP22_337_0703EN 393
 Generaltechnicaldescription

Programming a minimum speed

BP22_337_0703EN 2

" Set the Preselect boom speed" switch to User−defined

boomspeed".

" Select the store function.

" Press the function button to activate the store function.

" Turn the function button to select the Minimum boom speed"
symbol.

" Hold the function button pressed.

" Use the joystick to control the desired boom movement at the
same speed that is to become the minimum movement speed
for minimum joystick deflection.

" Release the function button first and then the joystick.

Note
The electronics in the radio remote control prevent you from pro
gramming a minimum speed that is higher than the maximum speed.

394 BP22_337_0703EN
 Generaltechnicaldescription

Preselecting your own boom speed

BP22_337_0703EN 3

Now when you set the Preselect boom speed" switch to User−
defined boom speed" and move the joystick to its full deflection, the
boom movement will be executed at the maximum movement speed
which you have just programmed. If you move the joystick only
slightly, the boom movement will be executed at the minimum move
ment speed which you have just programmed.

BP22_337_0703EN 395
 Generaltechnicaldescription

Menu 4 (with EBC) In Menu4 (with EBC) you can store limits for the placing boom.

Note
This menu is only available if the machine has an EBC control and
this is switched on.

1 2

5
4

BP22_313_0703EN 1

No. 0 Display Function / meaning

Shows the number of the menu currently displayed in
1 Menu line
inverse video and the menu selected is shown flashing.
Opens the submenu to store limits (only visible when
2 Arrow symbol for submenu
EBC selector switch is in switch position4)
The upper limit value is displayed
3 Upper limit
(measured from the height of the slewing head).
The left limit value is displayed
4 Left limit
(measured from the longitudinal axis of the truck).
The right limit value is displayed
5 Right limit
(measured from the longitudinal axis of the truck).
The lower limit value is displayed
6 Lower limit
(measured from the height of the slewing head).
Stored limits are displayed as symbols. If a symbol is
7 EBC status line
flashing, the boom has reached this limit.

396 BP22_313_0703EN
 Generaltechnicaldescription

Special features and symbols for Menu 4 (with EBC)

Limits If you have stored the limits, the stored values are displayed in the
corresponding field. At the same time, the corresponding symbol is
displayed in the status line (see EBC status line). The left and right
limits are measured from the longitudinal axis of the truck, where the
front is 0°. The limit to the left of the longitudinal axis of the truck is
negative, while the limit to the right of the longitudinal axis of truck is
positive.

Danger
Stored limits are only monitored in the Move end hose" EBC operat
ing mode (EBC selector switch in switch position 2). If you select a
different operating mode, there is a risk of inadvertent collision with
obstacles.

−30_ 0_

+120_

BP22_335_0703EN 1

Note
You can only program the left and right limits if the machine is fitted
with the appropriate equipment. If the equipment is not present,
novalue is displayed.

While no limits are stored, the fields always display the current value
(height of the boom tip above the zero line, position of the boom in
relation to the longitudinal axis of the truck).

BP22_335_0703EN 397
 Generaltechnicaldescription

EBC status line In normal conditions, the EBC status line is blank. The associated
symbol is only displayed if you have stored a limit or preferred posi
tion. The symbols are not displayed in a fixed position; they are filled
in from left to right in the sequence in which they appear. The follow
ing symbols can be displayed here:

Note
When the boom reaches a limit (upper, lower, slewing gear) in EBC
operation, the associated symbol flashes.

If the symbol is crossed out, it means that the EBC selector switch is
not in the Move end hose" switch position. Programmed limits are
not being monitored.

Upper limit
An upper limit is programmed. The measurement is from the height
of the slewing head to the boom tip. Arms cannot move above this
limit in the Move end hose" EBC operating mode (EBC selector
switch in switch position2).

Lower limit
A lower limit is programmed. The measurement is from the height of
the slewing head to the boom tip. Arms cannot move below this limit
in the Move end hose" EBC operating mode (EBC selector switch in
switch position2).

Slewing gear limit to the left

A left limit (to the left of the longitudinal axis of the truck) is pro
grammed. The boom cannot be moved beyond this limit in the
Move end hose" EBC operating mode (EBC selector switch in
switch position2).

Slewing gear limit to the right

A right limit (to the right of the longitudinal axis of the truck) is pro
grammed. The boom cannot be moved beyond this limit in the
Move end hose" EBC operating mode (EBC selector switch in
switch position2).

398 BP22_348_0803EN
 Generaltechnicaldescription

Slewing gear limit to the left and right

A left and right limit is programmed. The boom cannot be moved
beyond these limits in the Move end hose" EBC operating mode
(EBC selector switch in switch position2).

Preferred position for arm 1

A preferred position is programmed for arm1. In the Move end
hose" EBC operating mode (EBC selector switch in switch posi
tion2), arm 1 is no longer moved.

Preferred position for last arm

A preferred position is programmed for the last arm. In the Move
end hose" EBC operating mode (EBC selector switch in switch
position2), the last arm is no longer moved.

Preferred position for arm 1 and last arm

For the last arm and arm 1, a preferred position is programmed for
each. In the Move end hose" EBC operating mode (EBC selector
switch in switch position2), the last arm and arm 1 are no longer
moved.

Preferred position for arm 1 and arm 2

For arm 1 and arm 2, a preferred position is programmed for each.
In the Move end hose" EBC operating mode (EBC selector switch
inswitch position2), arm 1 and arm 2 are no longer moved.

BP22_348_0803EN 399
 Generaltechnicaldescription

Menu 6 Menu6 displays current limits.

BP21_723_0703EN 1

No. 0 Display Function / meaning

1 Menu line
Maximum concrete pressure,
2
digital
3 Maximum output, digital
4 Maximum engine speed
Shows the number of the menu currently displayed in
inverse video and the menu selected is shown flashing.
The set concrete pressure limit is displayed in
numbers (see the Pump settings" menu).
The set output restriction is displayed in numbers
(seethe Pump settings" menu).
The maximum possible engine speed is displayed.

3100 BP21_723_0703EN
 Generaltechnicaldescription

Menu 7 Menu7 displays any faults. If all fields are blank, there are no faults.

BP21_722_0703EN 1

No. 0 Display Function / meaning

Shows the number of the menu currently displayed in inverse
1 Menu line
video and the menu selected is shown flashing.
2 Fault status lines If faults exist, they are displayed.

BP21_722_0703EN 3101
 Generaltechnicaldescription

Symbols for Menu 7

Fault status lines In normal conditions, the fault status lines are blank. The associated
symbol is only displayed if there is a message. The symbols are not
displayed in a fixed position, but are filled in from the bottom left to
the top right in the sequence in which they appear. The following
symbols can be displayed:

Note
You will find further information about the displayed faults in the
description of the Ergonic Graphic Display" (display in the control
cabinet).

High pressure
The symbol is displayed if the pressure sensor on the main hydraulic
pump is defective.

Engine speed
The symbol is displayed if there is no speed of rotation signal
(e.g.engine speed sensor on the engine is defective).

3102 BP22_336_0904EN
 Generaltechnicaldescription

Hydraulic fluid overheating

The symbol is displayed if the temperature sensor in the flushing
fluid line of the main hydraulic pump measures at least 85°C or
isdefective.

Output current monitoring

The symbol is displayed if there is a fault on a monitored output. The
number of the defective output is displayed in the Ergonic Graphic
Display on the control cabinet.

Fault
The symbol is displayed if a fault has occurred.

EMERGENCY STOP
The symbol is displayed if an EMERGENCY STOP button is
operated.

BP22_336_0904EN 3103
 Generaltechnicaldescription

Magnetic switches
The symbol is displayed if one of the magnetic switches on the drive
cylinders is defective.

Insufficient hydraulic fluid pre-warning

The symbol is displayed if the hydraulic fluid level drops below the
monitored minimum value.

Boom fault
The symbol is displayed if there is a fault on the safety circuit control
cabinet".
The boom fault" symbol is an optional function only for overhead
rollandfold booms. These arm assemblies are monitored by the
safety circuit control cabinet".

Centralized lubrication system fault

The symbol is displayed if a fault is present in the centralized lubrica
tion system or if a lubricant reservoir is empty.

3104 BP22_342_1208EN
 Generaltechnicaldescription

Caution
The EBC control must no longer be used if an EBC component is de
fective. If even one space angle sensor or pressure sensor malfunc
tions, the EBC control will no longer function correctly. The machine
will have to continue to be operated without EBC functions if an EBC
component malfunctions. You must have the fault rectified by quali
fied personnel before using the EBC control again.

Pressure sensor
The symbol is displayed if an EBC pressure sensor has failed.

Space angle sensor

The symbol is displayed if an EBC space angle sensor has failed.

BP22_343_0703EN 3105
 Generaltechnicaldescription

Menu 8 The pump flow meter is shown in menu8. In this menu, you can read
off outputs in order to record job volumes on the construction site,
service intervals or the total output, for instance.

2 6

3 7

4 8

BP22_813_1103EN 1

No. 0 Display Function / meaning

Shows the number of the menu currently displayed
1 Menu line ininverse video and the menu selected is shown
flashing.
Setpoint value for the
2 The specified output is displayed.
output
Actual value for the
3 The output achieved is displayed.
output
Remaining value for the
4 The remaining output is displayed.
output
5 Switch The pump flow meter can be switched on/off(I/0).
Setpoint value for the The specified number of strokes based on the output
6
number of strokes is displayed.
Actual value for the
7 The number of strokes achieved is displayed.
number of strokes
The specified fill level is displayed (adjustable to
8 Fill level
between 70% and 100%).

3106 BP22_813_1103EN
 Generaltechnicaldescription

Method of operation of the pump flow meter

Output The output is calculated from the geometric data of the delivery cyl
inders at the fill level specified by you.

Switching the pump You can switch the pump flow meter on/off. When the pump flow
flow meter on/off meter is switched on, the concrete pump stops as soon as the speci
fied output is achieved. If you then switch the concrete pump off and
on again, the pump flow meter starts to count again from the speci
fied setpoint value.

Note
The pump flow meter is switched off in the works. As soon as the
radio remote control function is switched off, the settings are reset to
the factory settings.

If no setpoint value is specified for the output, the concrete pump

runs without parameters. The output displays still run. The values are
calculated using the set fill level.

Setpoint value for the You can specify a value for the output at which the concrete pump
output should switch off. The accuracy of the volumes indicated is depend
ent on the current fill level of the delivery cylinders. The more accu
rately you enter the fill level in percent, the more accurate the dis
play.

BP22_813_1103EN 3107
 Generaltechnicaldescription

Specifying a setpoint Enter the setpoint value for the output as follows:
value for the output
" Turn the function button to select the setpoint value.
å The setpoint value is displayed in inverse video.

" Then press the function button to activate the setpoint value.
å The first digit of the setpoint value flashes.

" Turn the function button to change the value as follows:

anti-clock- clockwise slowly quickly

wise
smaller larger in tenths in whole in
crements

" Press the function button to store the changed setting.

Note
If you change the setpoint value, the actual value and the remaining
value will be reset to0".

Actual / remaining Once the transfer tube has switched over for the first time, the actual
value for the output value starts to count the output achieved. The remaining value
shows the output still to be achieved at the same time.

As soon as the setpoint value is reached, the actual value and the
remaining value are reset to0".

Setpoint and actual The displayed numbers of strokes are calculated from the specified
value for number of setpoint value for the output and the geometric data for the delivery
strokes cylinder. The values cannot be adjusted manually.

3108 BP22_813_1103EN
 Generaltechnicaldescription

Entering the fill level of Enter the fill level of the delivery cylinders as described below:
the delivery cylinders
" Turn the function button to select the fill level.
å The fill level is displayed in inverse video.

" Then press the function button to activate the fill level.
å The fill level flashes.

" Turn the function button to change the value as follows:

anti-clock- clockwise slowly quickly

wise
smaller larger in tenths in whole in
crements

" Press the function button to store the changed setting.

Note
The usual fill level of the delivery cylinders is between 70% and
90% (average value: 85%). Use the formula to calculate the fill level
for your own concrete mix formula:

Amount of concrete in the truck mixer

Fill level = Number of strokes x (Volume of one delivery cyl
inder)

The specified fill level remains stored even when the radio remote
control is switched off.

BP22_813_1103EN 3109
 Generaltechnicaldescription

Calculation Amount of concrete in the truck mixer 8000dm3

example
Number of strokes
(Count the number of strokes, until you have 160
pumped the 8000dm3 of concrete.)

Volume of one delivery cylinder

(when D=230mm and L=1400mm)
58.16dm3
* D = diameter
* L = length

å Fill level 85%

3110 BP22_813_1103EN
 Generaltechnicaldescription

3.6.9 Radio remote control The charger is for charging the batteries for the radio remote control.
battery charger

Danger
There is a risk of fire if the following points are not observed.
 Only use this charger to charge batteries that are approved for the
radio remote control.
 Do not operate the charger in areas at risk from explosion.
 Only use the charger at the mains voltage noted on the charger.
 Use the charger in vehicles only.
 Only use the charger within the specified temperature range,
andprotect it from overheating, dust and moisture.
 Do not cover the charger while it is operating.
 Disconnect the charger from the mains supply when it is not in
use.
 Put the charger out of service immediately if there is a fault on the
charger or connecting cable.
 Do not make any technical changes to the charger or connecting
cable.
 Repairs must only be carried out by qualified electrical personnel.

BP23_097_1208EN 3111
 Generaltechnicaldescription

BP23_097_1208EN 1

No. 0 Designation
1 LEDs
2 Battery compartment
3 Vehicle connector

Battery charge state

Red indicator lamp The red indicator lamp lights up if the battery is in a state of deep
discharge or is defective.

Note
If a deepdischarge battery is inserted into the charger, the red
indicator lamp lights up for a few seconds before the charging
operation begins.

Yellow indicator lamp The yellow indicator lamp lights up during the battery charging
operation.

Green indicator lamp The green indicator lamp lights up once the battery is charged and
the charging operation is complete.

3112 BP23_097_1208EN
 Generaltechnicaldescription

3.6.10 EMERGENCY STOP There are a number of EMERGENCY STOP buttons on the machine.
button These are located:
− on every support control block
− on the cable and radio remote control systems
− on the control panel or on the control cabinet

Some possible positions of the EMERGENCY STOP buttons are

shown in the figure below.

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

Á Á
Á
ÁÁ ÁÁ
ÁÁ
30505901

EMERGENCY STOP button

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

To release the EMERGENCY STOP condition again, you must unlock

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

You must switch the pump off and back on again to restart the pump.

BP23_012_1112EN 3113
 Generaltechnicaldescription

The following actions are triggered in the truck, pump, agitator and
boom systems when you press one of the EMERGENCY STOP
buttons:

System Action

Truck − Engine speed drops to idle.

− It is no longer possible to set the engine speed
electrically.
Pump − The EMERGENCY STOP operated" indicator
lamp lights up on the control cabinet.
− Variable main pumps swing back, the delivery
pistons come to a halt.
− The change−over valve is disconnected.
Agitator − The agitator will stop.
Boom − The boom control unit is disconnected.
− The supply voltage to the entire radio remote
control system is switched off, all indicator
lamps on the radio remote control unit go out.
− On the cable remote control system, the supply
voltage is switched off with the exception of that
for the horn, the Fault" indicator lamp on the
cable remote control unit lights, the Pump on"
indicator lamp flashes.
− The boom pump transports hydraulic fluid in
depressurized circulation (maximum15bar)
through the boom control unit inlet module to
the reservoir. Emergency operation of the boom
functions is ensured by simultaneous manual
operation of the operating mode selector valve
and the corresponding boom arm valve.

3114 BP23_012_1112EN
 Generaltechnicaldescription

Danger
The machine is only switched off electrically when the EMERGENCY
STOP button is pressed. Although this causes all the electrically
actuated hydraulic valves to be switched off, an unexpected sinking
of the boom caused by leaks in the hydraulic system, for instance,
cannot be prevented in this way.

In no event should you first press the EMERGENCY STOP button if

the boom starts unexpected movements. Should you do this you will
have no ability to counteract the movement.

BP23_012_1112EN 3115
 Generaltechnicaldescription

3.6.11 Magnetic switches The distributor casing for the magnetic switches is located next to
distributor casing the drive cylinders of the concrete pump on the right−hand side
(when viewed in the direction of travel). The following illustration
shows an example.

Note
Drive cylinder1 is the right−hand cylinder when viewed in the direc
tion of travel.

The magnetic switches and their function are monitored by the pump
control system software and illustrated in the display on the control
cabinet. The distributor casing also provides a visual display of the
functions.

2
1

4
3
1 2

BP21_733_0604EN 1

No. 0 Meaning/Function
Schematic illustration of the magnetic switch installation
1
locations and numbering
2 Schematic illustration of the plate on the distributor casing
Magnetic switches distributor casing with indicator
lamps:
3
one yellow LED for each connection
one green LED for the casing (in service lamp)

3116 BP21_733_0604EN
 Generaltechnicaldescription

Special features of the distributor casing

Indicator lamps There are two magnetic switches on each drive cylinder of the core
pump, one at the rod side and one at the piston side. These switches
trigger the switchover procedure when the hydraulic pistons approach
the magnetic switches. The indicator lamps for the magnetic switches
that have just been triggered light up on the distributor casing at the
same time.

Indicator lamp (number) Magnetic switch status

lights up briefly on switchover Magnetic switch is OK

does not light up on switchover Magnetic switch, connector or

lead are defective, replace at
the earliest opportunity

lights up continuously Magnetic switch, connector

orlead are defective, remove
connector from the switch
(otherwise switchover is not
possible) and replace at the
earliest opportunity

In service lamp Distributor casing status

lights up continuously The distributor casing is ready

for operation.

does not light up The power take−off is not

engaged and the Putzmeister
operating system is not supplied
with a voltage.

Note
Additional LEDs are located on the magnetic switch connector
(seepage 3118). These LEDs indicate whether it is the magnetic
switch or the connector and lead that is defective.

BP21_733_0604EN 3117
 Generaltechnicaldescription

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

1 2

20500406

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

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

3118 BP02_428_9707EN
 Generaltechnicaldescription

Significance of
Yellow LED Magnetic switch status
the LEDs
lights up briefly on switchover Magnetic switch is in order

does not light up on switchover Magnetic switch is defective,

replace at earliest opportunity

lights up continuously Magnetic switch is defective,

remove connector from the
magnetic switch (otherwise
switchover is not possible) and
replace at earliest opportunity

Green LED Connector and lead status

lights up A voltage is being applied to the

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

does not light up No voltage is being applied to

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

BP02_428_9707EN 3119
 Generaltechnicaldescription

3.6.13 Agitator safety cutout
(RSA)
The agitator safety cutout consists of a transponder and an evalu
ation device with reading head. As soon as you open the grille, the
radio link between the transponder and reading head is broken. This
causes the agitator to halt and the pressure to be dumped from the
accumulator, i.e. the transfer tube will no longer be able to switch
over. In addition, the delivery pistons return to the end position and
the concrete pump halts. You must switch the concrete pump off and
back on again to restart it. So that the agitator starts turning again
and the accumulator refills, the agitator safety cutout on the control
panel in the steps must be acknowledged.

1 2 3 4 BP22_906_1111EN 1

No. 0 Designation
1 Reading head (on the hopper − example photograph)
2 LED, green and red
3 Transponder (in the grille)
4 Acknowledge the agitator safety cutout

3120 BP22_906_1111EN
 Generaltechnicaldescription

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

Therefore, always check that the agitator safety cutout is working

properly before using the pump.

The LED on the evaluation device has the following display:

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

BP22_906_1111EN 3121
 Generaltechnicaldescription

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

The hydraulic control devices may include the following components,

depending on the equipment on your machine.
− Support control block
− Boom functions control block
− Emergency hydraulic ports
− Agitator lever
− Water pump lever
− Compressor lever
− Output controller
− Accumulator dump cock
− Transfer tube damping cock

Note
Further control devices and components are described in the
Electrical control devices" (from page 318) and Othercompo
nents" (from page 3129) sections.

3122 BP02_389_9704EN
 Generaltechnicaldescription

3.7.1 Support control block The support control block on the left−hand side of the truck (driver’s
side) is illustrated below. The support control block on the right−hand
side of the truck (passenger side) is a mirror image of this one.

1 2 3 4 5 6

BP23_142_1212EN 1

No. 0 Designation
1 EMERGENCY STOP button
2 Preselect lever for support function ON/OFF
3 Raise and lower forward support foot
4 Raise and lower rear support foot
5 Extend and retract forward support leg
6 Swing rear support leg out and in

BP23_142_1212EN 3123
 Generaltechnicaldescription

Special features of the support control block

Two−hand control The support control block is designed as a two−hand control device,
device i.e. to execute a function, you must operate the preselect lever and
the corresponding function lever simultaneously.

Spring−loaded The hydraulic support valves are springloaded, i.e. the valves are
automatically reset to the zero position when you release the levers.

Direction of operation

BP23_142_1212EN 2

The levers must be moved up and down or forwards and backwards

to execute the support functions depending on the installation posi
tion of the control block or operating levers.

3124 BP23_142_1212EN
 Generaltechnicaldescription

Spirit level A spirit level is fitted on both sides of the machine in the immediate
vicinity of the support control block". The spirit levels are a visual
aid for setting up the machine horizontally within the permissible
tolerance.

5d
3d

BP21_782_0407EN 1

Danger
If the machine deviates from the horizontal by more than 3°, the
boom and the boom pedestal are excessively loaded. Furthermore,
the stability of the machine is jeopardised.

The spirit levels are fitted in such a way that you can easily check
that the machine is level while it is being supported. If the spirit
levels or their brackets are damaged, the level position of the
machine cannot be guaranteed.

For this reason, check both spirit levels and their brackets for visible
damage daily. Have any damage rectified immediately by Putzmeister
qualified personnel. Damage has also occurred if the displays in the
two spirit levels differ.

Furthermore, the spirit levels must undergo an annual inspection.

The result of the inspection must be documented in the check book
and confirmed by the inspector.

BP21_782_0407EN 3125
 Generaltechnicaldescription

3.7.2 Boom control block The arm assembly can be operated manually at the boom control
block in the event of a remote control malfunction.

Caution
Lock the stowage compartment to ensure that unauthorized persons
are not able to gain access to the boom control block.

Note
The guard on the boom control block must be fitted during normal
operation. This will ensure that the emergency control levers can only
be operated in the event of a fault.

2
BP23_118_1209EN 1

No. 0 Designation
1 Boom control block: emergency control levers for boom
functions
2 Guard

3126 BP23_118_1209EN
 Generaltechnicaldescription

3.7.3 Pump control system The hydraulic control valves are built into the pump control system.
The concrete pump can be operated manually at the pump control
system if a machine malfunction occurs
(see service instructions, chapter Special operating modes").

Danger
There is an increased risk of accidents during a special operation. A
special operation must only be carried out if:
 you have been trained for these activities by the machine manu
facturer
 you have been authorized for these activities by the machine oper
ating company

The guard is secured with sensors. Once you remove the guard, the
EMERGENCY STOP function is triggered. This then puts the safety
functions out of service.

To ensure that unauthorized persons are not able to gain access to

the pump control system, this is located behind guard.

4
3
2
BP23_119_1209EN 1

No. 0 Designation
1 Transfer tube damping cock
2 Accumulator dump valve
3 Pump control system (behind guard)
4 Agitator and water pump control block (behind guard)

BP23_119_1209EN 3127
 Generaltechnicaldescription

3.7.4 Centralized The centralized gauge ports bring together all the measuring points
gauge ports on the machine, making it easier to measure pressures. You can find
the setpoint values for each of the measuring points in the machine’s
test reading (see the Technical data" binder).

Caution
The centralized gauge ports integrate a high pressure and a low−
pressure gauge. Never connect the low−pressure gauge to high−
pressure measuring points marked with red, as this could cause
them to break.

1 3

2 4

BP22_729_0809EN 1

No. 0 Designation
1 High−pressure gauge
2 High−pressure measuring points
3 Low−pressure gauge
4 Low−pressure measuring points

3128 BP22_729_0809EN
 Generaltechnicaldescription

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

The following components may be described here, depending on

the equipment on your machine.
− Manual throttle lever for the truck engine
− End hose
− Flushing water pump
− High−pressure water pump
− Compressor
− Vibrator
− Hydraulic fluid radiator

Note
Further control devices and components are described in the
Hydraulic control devices" (from page 3122) and Electrical con
trol devices" (from page 318) sections.

BP02_390_9704EN 3129
 Generaltechnicaldescription

3.8.1 End hose The machine is fitted with an end hose which complies with stability
and occupational safety requirements. This depends on a number of
factors:
− on the loadbearing capacity of the placing boom at the boom tip,
− on the gross weight of all fittings at the boom tip.

Note
The permitted gross weight of the fittings at the boom tip, including
concrete filling, can be found in the machine documentation.
The machine card for this machine will tell you which end hose is ap
proved for the machine. The maximum permissible end hose length
is also indicated on the boom rating plate.

Danger
The machine is at risk of toppling over if the gross weight of all fit
tings (e.g. including the squeeze valve) at the boom tip including
concrete filling exceeds the maximum loadbearing capacity of the
placing boom.

The gross weight of all fittings at the boom tip including concrete fill
ing must not exceed the maximum loadbearing capacity of the plac
ing boom.
As a result, you must only use the end hoses specified by the manu
facturer in your machine documentation.

You may only use a different end hose (e.g. a longer end hose to fill
deep formwork) if this is expressly described in these Operating In
structions (see Use of the xm end hose" section).

3130 BP02_371_1111EN
 Generaltechnicaldescription

End hose with flow End hoses must not be fitted with any extension coupling, outlet
restrictor shoes or other dangerous outlet fitting. In order to achieve an even
flow of the concrete however, you can use the restrictor devices
which have been approved by Putzmeister.
When selecting a restrictor device, you must match the permitted
gross weight of all fittings at the boom tip including concrete filling
with the loadbearing capacity of the placing boom.

Danger
In order to prevent injury to the operator (e.g. through being struck
by the end hose), the rubber protective sleeve must always be fully
pulled down over the pushin spout, regardless of whether you fit the
flow restrictor or not. The end hose may no longer be used if the pro
tective sleeve is damaged or missing entirely.
In order to prevent injury to the operator, even the restrictor devices
must not exhibit any metal surfaces on their outside.

ÂÂ
ÂÂ
Products supplied

ÂÂ
ÂÂ
1
ÂÂ
2 ÂÂ
ÂÂ
3
ÂÂ
4

BP02_371_1111EN 1

No. 0 Designation
1 Rubber protective sleeve
2 Modified end hose
3 Pushin spout
4 Flow restrictor

BP02_371_1111EN 3131
 Generaltechnicaldescription

Retaining rope The end hose is permanently exposed to high loads and severe
on the end hose wear. It is, therefore, possible that a heavily worn end hose may tear
at the pushon connection. The retaining rope prevents the end hose
from falling.

2 ÂÂÂ
ÂÂÂ
3

ÂÂÂ
ÂÂÂ 4

ÂÂÂ BP02_371_1111EN 2

No. 0 Designation
1 Snap hook
2 Retaining rope
3 Pushon connection
4 Hose clamp

Danger
The retaining rope prevents the end hose from falling if it tears away
or if the coupling is opened. The end hose must therefore always be
secured by a retaining rope.

The retaining rope must be passed around one of the clamping bolts
on the hose clamp and secured to the boom by the snap hook.
Fastening the retaining rope to the coupling is prohibited as the end
hose would fall when the coupling was opened.

Check the retaining rope for damage every day. A damaged retain
ing rope must be replaced by a new retaining rope immediately.

3132 BP02_371_1111EN
 Generaltechnicaldescription

Dual-section end hose In this section, the assembly of a split end hose with a protective bell
with protective bell is illustrated.

Danger
In order that the split end hose is secured against falling off, the de
livery hose must be secured with a retaining rope attached to the
boom tip and the end hose with another retaining rope attached to
the delivery hose. Check the retaining ropes for damage every day.
A damaged retaining rope must be replaced by a new retaining rope
immediately.

The connection point between the delivery hose and end hose is lo
cated overhead. In order to minimize the risk of injury to the hose
man however, the protective bell must always be pulled down over
the connection point.

The gross weight of all fittings at the boom tip including concrete fill
ing (in this case the weight of the split end hose with protective bell
and couplings), must not exceed the maximum loadbearing capacity
of the placing boom, as otherwise the machine may topple over or
suffer longterm damage.

The dualsection end hose may only be used in the fullyassembled

condition. The lower end may not be fitted with any extension coupl
ing, outlet shoes or other dangerous outlet fitting. There is otherwise
a risk of injury if the end hose swings out.

BP02_371_1111EN 3133
 Generaltechnicaldescription

4
5
6

10

11

BP02_371_1111EN 3

No. 0 Designation
1 Delivery hose
2 Protective bell
3 Pushon connection
4 Hose clamp
5 Securing bolt with nut
6 Seal ring
7 Clamp coupling
8 Retaining rope with two snap hooks
9 Hose clamp
10 Pushon connection
11 End hose

3134 BP02_371_1111EN
 Generaltechnicaldescription

Protective sleeve In order to minimize the risk of injury to the hoseman, there is alterna
with Velcro fastener tively also a protective sleeve with Velcro fastener. The Velcro fas
tener allows the delivery and end hoses to be changed easily and
quickly.

5
BP02_371_1111EN 4

No. 0 Designation
1 Delivery hose
2 Protective sleeve
3 Clamp coupling
4 Velcro fastener
5 End hose

BP02_371_1111EN 3135
 Generaltechnicaldescription

3.8.2 Flushing water pump The flushing water pump generates a maximum water pressure
of25bar and a maximum water delivery rate of 160litres per minute.

1
5

4
2

BP02_362_9803EN 1

No. 0 Designation
1 Pressure gauge for water pressure
2 Water hose connection
3 Flushing water pump
4 Hydraulic ports
5 Hydraulic motor

3136 BP02_362_9803EN
 Generaltechnicaldescription

3.8.3 Water box The devices for draining and filling the water box are described
below.

Caution
Risk of the concrete pump overheating if the fill level in the water box
is too low.
Check the water fill level in water box regularly. As required, fill the
water box with cold and clean water in order to prevent the concrete
pump from overheating and other subsequent damage.

When emptying the water box, check the condition of the water −
particularly that it is clean.
 A chalky white colour is a sign of cement in the water.
This is an indication of damaged delivery pistons.
 An unusual amount of hydraulic fluid in the water indicates that the
drive cylinders are leaking.

Damage to the delivery pistons or drive cylinders must be rectified

immediately. Putzmeister accepts no warranty claims for damage to
the machine resulting from failure to properly observe the mainten
ance regulations.

BP22_994_1111EN 3137
 Generaltechnicaldescription

2 3
7

BP22_994_1111EN 1

No. 0 Designation
1 Plan view of the machine
2 Water tank
3 Water box fill cock
4 Lid with seal
5 Grille
6 Water outlet
7 Water box

3138 BP22_994_1111EN
 Generaltechnicaldescription

3.8.4 Vibrator The vibrator is bolted to the grille. It causes the grille to vibrate and
thus prevents bridges forming on the grille, particularly in the case of
very stiff concrete. The vibrator is electrically driven. This requires
that the connector be plugged into the appropriate round socket.
The round socket may be found on the control cabinet or in a separ
ate plastic housing near the hopper.

1
3

4
31201000

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

The vibrator is switched on and off either at the control cabinet or on

the control panel by the steps.

BP02_329_9707EN 3139
 Generaltechnicaldescription

3.8.5 Hydraulic fluid The machine is fitted with a hydraulic fluid radiator with 2fans. Some
radiator of the hydraulic fluid in the machine first flows through this hydraulic
fluid radiator before it returns to the filter. The fans on the hydraulic
fluid radiator can be switched on by twotemperature sensors or
manually.
− A 70_C temperature sensor is fitted on the hydraulic fluid radiator.
This temperature sensor measures the temperature of the
collected boom return fluid, agitator return oil and flushing fluid.
− The second temperature sensor is mounted in the leakage oil line
of the main hydraulic pump. This temperature sensor measures
the temperature of the leakage oil for the main hydraulic pump
andhas switching values of 55_C, 85_C and 90_C.

4 6
1

3 5 7 5
BP22_936_1104EN 1

No. 0 Designation
1 Boom return circuit fluid
2 Agitator return oil
3 Flushing fluid
4 Radiator with twofans
5 Temperature sensors
6 Leakage oil
7 Hydraulic fluid reservoir

3140 BP22_936_1104EN
 Generaltechnicaldescription

4
5
20204201

No. 0 Designation
1 Symbol for hydraulic fluid radiator
2 Hydraulic fluid return from cooler
3 Fan
4 Hydraulic fluid to cooler
5 Temperature sensor 70_C

BP22_936_1104EN 3141
 Generaltechnicaldescription

Special features of the hydraulic fluid radiator control system

This circuit offers both a redundant safety system and cooling of the
hydraulic fluid if only the boom is being moved or only the concrete
pump is running.
− Initially, one of the two fans on the hydraulic fluid radiator switches
on once the leakage oil from the main hydraulic pump reaches a
temperature of 55_C.
− If the hydraulic fluid from the cooler reaches a temperature of
70_C, both fans switch on.
− If the main hydraulic pump leakage oil reaches a temperature of
85_C, the output is reduced gradually.
− If the main hydraulic pump leakage oil reaches a temperature of
90_C, the concrete pump switches off.

Note
You may switch on both fans at the same time at the control cabinet,
whatever the fluid temperature, should you wish to cool the hydraulic
fluid before it has reached 55_C or 70_C as a precautionary mea
sure. As soon as one of the two fans begins running, this is shown
onthe control cabinet.

For optimal operation of the machine, the temperature of the

hydraulic fluid should not drop below 40_C.

Leave the truck engine running during breaks in pumping or when

pumping is completed until the fan motors switch themselves off.

The hydraulic fluid is also cooled by the water in the water box.
Thehydraulic fluid warms up the piston rods for the drive cylinders.
These are flushed, and thus cooled, by the water in the water box
oneach stroke movement. This also cools the hydraulic fluid.
Youshould therefore change the water in the water box at frequent
intervals.

3142 BP22_936_1104EN
 Generaltechnicaldescription

3.8.6 Microfilter The microfilter is integrated in a hydraulic line which leads back to
the reservoir. A bypass and a throttle valve ensure that a maximum
of8litres of hydraulic fluid flows through the filter each minute at a
maximum pressure of 5bar. A pressure gauge displays the pressure
in the microfilter housing. If, for hydraulic fluid still warm from use
(50−60_C), the pressure gauge displays a hydraulic fluid pressure
of 4bar (marked in red), the filter element needs to be replaced.
Ashut−off valve prevents the fluid from leaking out when the filter
element is replaced.

BP02_433_0705EN 1

No. 0 Designation
1 Microfilter
2 Pressure gauge
3 Shut−off valve

Danger
Whilst in operation, the hydraulic fluid and also the filter housing can
heat up to a temperature of 70_C. You should therefore refrain from
touching the filter housing during or shortly after operating the filter.

Note
When the filter is in operation, the shut−off valve must be open, other
wise, no hydraulic fluid will be able to flow through the microfilter.

BP02_433_0705EN 3143
 4 Driving, towing and loading

In this section you will find information concerning safe transport of

the machine.

BP04_001_9404EN
 Driving,towingandloading

4.1 Driving Truck−mounted concrete pump and trailer pumps may only be
driven on public highways if they are licensed accordingly. The
driver must have the relevant driving licence.

If you have to drive in reverse you must always ask for a marshaller
to guide you. If necessary, have the route blocked or secured by as
sistants. Have the site management arrange for the removal of any
materials or equipment that hinder your approach.

Agree clear hand signals with the marshaller before moving off.

4.1.1 Hand signals

10000331

See the section on Hand signals for driving" for hand signals

BP04_002_9411EN 41
 Driving,towingandloading

4.1.2 Before moving off Before you join the public highway, you must carry out the following
actions:

" Check that the vehicle is safe to drive (lighting, brakes, tyre
pressures, etc.).

" Check that the accessories and the load are secure.

" Check that the support legs are secured in the transport posi
tion.

" Observe the permissible gross laden weight.

" Check that the oil and water reservoirs are not leaking and that
they are securely closed.

" Switch the power take−off off.

Danger
Supports extending spontaneously whilst the truck is moving can
cause serious accidents.

Close the hydraulic shut−off valves in the support system and fit the
transport security devices (e.g. spring pins on all snaplocks).

42 BP04_002_9411EN
 Driving,towingandloading

4.1.3 During the journey The size and weight of the truck demand particular caution when
driving.

" Keep an adequate distance from slopes and pits.

" Only drive over arches, bridges or other supporting structures

if the loadbearing capacity is adequate.

" Be aware of the height of the truck in underpasses, under

bridges and similar.

" Be aware of the elevated position of the truck’s centre of gravity

when travelling on a slope and on ascending or descending
routes.

Danger
The truck may never be driven with the placing boom unfolded. This
may cause the truck to tip over.

12000100

Never drive the truck with the boom unfolded.

BP04_002_9411EN 43
 Driving,towingandloading

4.2 Hand signals It is often necessary to have a signaller help by directing you when
for driving you are driving to the set−up site on construction sites where space
is restricted. Clear hand signals must be agreed between signaller
and machine operator. Below you will find some suggestions for
hand signals to be used when driving.

Stop Extend both arms out

totheside.

BP04_003_0610EN 2

Drive to the left With the arm crooked, point

with the thumb in the direction
the truck should steer.

BP04_003_0610EN 3

Drive to the right With the arm crooked, point

with the thumb in the direction
the truck should steer.

BP04_003_0610EN 4

44 BP04_003_0610EN
 Driving,towingandloading

Drive towards With the arm crooked, wave the

the signaller palm in the direction the truck
should drive.

BP04_003_0610EN 5

Drive away from With the arm crooked, wave the

the signaller palm in the direction the truck
should drive.

BP04_003_0610EN 6

Clearance With the arm crooked, indicate

the distance to an obstacle with
the palms of the hands.

BP04_003_0610EN 7

BP04_003_0610EN 45
 Driving,towingandloading

4.3 Towing The truck may only be towed in accordance with the truck manu
facturer’s rules. Use the towing equipment provided.

Caution
Only use the towing eye on the rear of the truck for assistance on the
construction site if a tow−bar cannot be fitted to the front of the truck.
Never tow the truck by the pump unit or the hopper.

20007501

Tow coupling on the front of the truck

A coupling is fitted on the front of the truck for breakdown rescue or

towing the truck.

46 BP04_004_9707EN
 Driving,towingandloading

40000204

Caution
If you wish to tow the machine from the towing eye on the rear swing
ing support leg, the swinging support leg must be swung fully in,
and the direction of towing must be along the truck axis. Serious
damage may be caused to the boom pedestal, the swinging support
leg and the slewing cylinder if the swinging support leg is swung out,
or if you tow at an angle.

Make sure that the towing rope or the tow−bar does not damage the
hopper or other parts of the bodywork if you use the towing eye near
the hopper.

BP04_004_9707EN 47
 Driving,towingandloading

10000400

Towing eye on the rear of the truck

You must use the towing eye on the rear of the truck to tow the truck
from the rear.

40000203

Towing eye

The towing eye on machines with TRS60 or TRS70 boom pedestals

is mounted over the compartment housing the rear support.

48 BP04_004_9707EN
 Driving,towingandloading

40000201

Towing eye on the support cylinder

The lifting eye on the support cylinder may be used as the towing
eye on M42 and larger machines.

40000202

Towing eye at the rear of the swinging support leg

The towing eye on machines with TRDI60 or TRDI70 boom

pedestals is mounted on the rear of the swinging support leg.

BP04_004_9707EN 49
 Driving,towingandloading

4.4 Loading The standard slinging hooks fitted to the machine are there for as
sembly purposes only. Slinging hooks suitable for lifting the complete
machine can be ordered on a new machine and may, possibly, be
retro−fitted to an old machine.

If your machine is fitted with suitable slinging hooks, they will be

identified as follows.

10002400

Plate for slinging hooks

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

410 BP04_005_9411EN
 Driving,towingandloading

Caution
The machine may only be loaded by crane if it is equipped with suit
able slinging hooks. Lifting equipment, lifting tackle, supports and
other auxiliary equipment shall be safe in use and operation. Make
sure that the loadbearing capacity is adequate.

10000600

Do not lift the machine by the assembly slinging points

BP04_005_9411EN 411
 5 Operation

In this chapter you will find information on the operation of

themachine. You will learn what operations are required for
commissioning, for setting up the machine, in pumping
operationsand for cleaning.

BP07_001_9404EN
 Operation

5.1 Starting up When you take over the machine, you must become so familiar with
the equipment that damage and accidents cannot occur.
Every time you use the machine, you accept full responsibility for the
safety of anyone located in the machine’s danger zone. You are
therefore under an obligation to ensure that the machine is com
pletely safe in operation.

5.1.1 Test run Carry out a test run and function checks before commencing work
on the construction site.

Immobiliser Many trucks are fitted with an immobiliser to safeguard them from
theft. To prevent accidental triggering of the immobiliser, please read
the operating instructions provided by the truck manufacturer before
starting the engine.

BP07_019_0309EN 51
 Operation

5.1.2 Functional fluids

10000700

Water, oil and fuel levels

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

" Check all water, oil and fuel levels and top these up as necess
ary.

Caution
The water temperature may not exceed 60°C (140°F) if your ma
chine is equipped with a plastic water tank. There is a risk of the
water tank deforming at higher water temperatures.

Note
The machine must be level when you check the functional fluids. The
boom and the supports must be retracted. The water box on con
crete pumps must be full during operation, even if there is a risk of
freezing.

52 BP07_019_0309EN
 Operation

5.1.3 Engaging the The transfer gearbox is installed after the truck gearbox in the
transfer gearbox Cardan shaft line.
power take–off
The following information describes how a manual gearbox is
operated. In the case of an automatic gearbox, also check the
dataprovided by the vehicle manufacturer.

Caution
The following points must be complied with in order to prevent
damage when using the transfer gearbox:
 Only engage the transfer gearbox when the engine is running and
after operating the clutch.
 When engaging and disengaging the transfer gearbox, the vehicle
gearbox must be in the neutral position. The Cardan shaft must not
turn.
 The engine may only be restarted after it has been shut down
during pumping operations if the concrete pump is switched off
and the pumping rate has been turned down to 0".

Note
You must apply the parking brake before you engage the power
take−off if your truck engine is equipped with electronic diesel
control (EDC). Otherwise you will not be able to increase the engine
speed during pumping operations. This is also the case if you
release the parking brake and apply it again while the power take−off
is engaged.

BP07_553_0809EN 53
 Operation

3a

1 2 3

3b

BP07_553_0809EN 1

No. 0 Designation
1 Green indicator lamp
2 Red warning lamp
3 Locally latched toggle switch
3a Pumping operations" switch position
3b Driving" switch position

Note
To use a locally latched toggle switch, you must first pull it out and
then push it towards the symbol.

54 BP07_553_0809EN
 Operation

" Apply the parking brake.

" Operate the clutch pedal.

" Shift the vehicle gearbox to the neutral position.

" Switch the locally latched toggle switch in the driver’s cab
fromdriving to pumping operations.
å The green indicator lamp in the dashboard lights up.

" Select direct drive − unless otherwise specified − (see informa

tion plate in the truck) and slowly release the clutch pedal.
(Direct drive: Cardan shaft speed=engine speed)

Note
If the green indicator lamp does not light up at this point, it is because
the gear shift lasts several seconds. Normally, the lamp lights up
after this time and the machine is then ready to pump.

BP07_553_0809EN 55
 Operation

Rectifying shifting If there is a shifting fault in the transfer gearbox, rectify the fault as
faults in the transfer follows:
gearbox
Danger
The machine is not ready to pump until the fault has been rectified. If
you continue pumping after switching to pumping operations despite
the fault, this will lead to damage to the transfer gearbox and the
truck.

" Run the engine.

" Apply the parking brake.

" Shift the vehicle gearbox to the neutral position and keep the
clutch pedal depressed.

" Switch the locally latched toggle switch from pumping oper
ations back to driving.

" Switch the locally latched toggle switch from driving back to
pumping operations.

" Select direct drive − unless otherwise specified − (see informa

tion plate in the truck) and slowly release the clutch pedal.
(Direct drive: Cardan shaft speed=engine speed)
å The green indicator lamp in the dashboard lights up.

56 BP07_553_0809EN
 Operation

Caution
If you hear a clattering noise from the gearbox, depress the clutch
pedal immediately and repeat the shifting procedure. Incorrect oper
ation during the shifting procedure can result in gearbox damage.

Danger
If there is still a shifting fault in the transfer gearbox, you may only
repeat the procedure 2 to 3 times without causing any damage.
If a shifting fault cannot be rectified, contact the Putzmeister after−
sales service (APS department).

BP07_553_0809EN 57
 Operation

5.1.4 Remote control Depending on your machine’s equipment, you can operate it
− with the radio remote control,
− with the cable remote control or
− directly on the machine in emergency operation.

Caution
Carry the remote control in such a way that no control elements
canbe actuated unintentionally. Do not damage the remote control
cable. Malfunctions may otherwise occur.
Never put the remote control down when the machine is ready for
operation. If this is unavoidable in exceptional cases, you must
switch off the remote control, disconnect it and lock it away.

Danger
Risk to life from unintended machine movements. The range of
aradio remote control is great enough for the machine to receive
control commands (e.g. from a great distance, from inside enclosed
spaces), even without visual contact. In such cases, signallers MUST
be used, and must remain in contact with the machine operator
using suitable means, and have visual contact with the site of
concrete placement, work and danger zones and the machine.

58 BP07_051_1109EN
 Operation

Radio remote control When using the radio remote control, boom movement is propor
tional to the movement of the joystick, i.e. the further you move the
joystick, the faster the boom moves.

Connecting The radio remote control receiver is connected to the control cabinet.

1 2 3

BP07_822_1208EN 1

No. 0 Designation
1 Radio remote control
2 Charger/receiver
3 Control cabinet

BP07_822_1208EN 59
 Operation

Starting up To start up the machine using the radio remote control, proceed as
follows:

ÁÁÁ
2 3 4 5 6

ÁÁÁ
ÁÁÁ
ÁÁÁ
1

BP07_822_1208EN 2

No. 0 Designation
1 Radio remote control
2 STOP button
3 Indicator lamp
4 Radio remote control unit ON/OFF" toggle switch
5 Forward pumping − 0 − Reverse pumping" toggle switch
6 Horn + deactivate EMERGENCY STOP / Changeover"
toggle switch

" Switch the Local control − 0 − Remote control" toggle switch

on the control cabinet(3) to Remote control".

" Unlock the STOP button(2) by turning it.

" Use the Radio remote control unit ON/OFF" toggle switch(4)
to switch the radio remote control(1) on.
å While the radio remote control(1) is starting up, the indica
tor lamp(3) will flash green twice a second.
å After 5to 10seconds, when the radio remote control(1) is
ready for operation, the indicator lamp(3) will flash green once
a second.

510 BP07_822_1208EN
 Operation

" Operate the Horn + deactivate EMERGENCY STOP / Change

over" toggle switch(6).
å The EMERGENCY STOP circuit is deactivated.
å The machine is ready for operation.

Starting up after a To start up the machine again after having stopped it using the STOP
STOP button(2) on the radio remote control(1), proceed as follows:

" Unlock the STOP button(2) by turning it.

" Use the Radio remote control unit ON/OFF" toggle switch(4)
to switch the radio remote control(1) on.
å While the radio remote control(1) is starting up, the indica
tor lamp(3) will flash green twice a second.
å After 5to 10seconds, when the radio remote control(1) is
ready for operation, the indicator lamp(3) will flash green once
a second.

" Operate the Horn + deactivate EMERGENCY STOP / Change

over" toggle switch(6).
å The EMERGENCY STOP circuit is deactivated.

" Switch the pump off and then back on again using the For
ward pumping − 0 − Reverse pumping" toggle switch(5).
å The machine is ready for operation.

BP07_822_1208EN 511
 Operation

Changing the battery If the indicator lamp(3) flashes red, the battery(1) is flat and must
be replaced.

1 2 3
BP07_822_1208EN 3

No. 0 Designation
1 Battery
2 Cutout in the battery compartment
3 Indicator lamp

" Switch the radio remote control off.

å The indicator lamp(3) goes out.

" Push the battery(1) to the left.

" Pull out the battery(1).

BP07_822_1208EN 4

" Hold the fully charged battery(1) in such a way that the label is
on the front to the left.

" Insert the battery(1) into the battery compartment.

å The battery(1) snaps into place.

512 BP07_822_1208EN
 Operation

Charging the battery on

the receiver

1 2 3 4 5
BP07_822_1208EN 5

No. 0 Designation
1 Charger/receiver
2 Battery
3 Yellow indicator lamp: battery charging
4 Green indicator lamp: battery fully charged
5 Cutout in the compartment

Note
The yellow indicator lamp(3) lights up during the battery charging
operation.
The green indicator lamp(4) lights up once the battery is charged
and the charging operation is complete.

" Push the charged battery(2) downwards.

" Pull out the battery(2).

BP07_822_1208EN 513
 Operation

BP07_822_1208EN 6

" Hold the battery that is to be charged(2) in such a way that the
label is on the front towards the bottom.

" Insert the battery(2) into the compartment.

å The battery(2) snaps into place.
å The yellow indicator lamp(3) lights up during the battery
charging operation.

Note
When the battery(2) is charged, the charging operation stops, which
means that it is not possible to overcharge the battery(2).

514 BP07_822_1208EN
 Operation

Charging the battery

with a separate charger

1 4

BP07_822_1208EN 7

No. 0 Designation
1 Battery
2 LEDs
3 Battery compartment
4 Vehicle connector

Note
The red indicator lamp lights up if the battery is in a state of deep
discharge or is defective. The yellow indicator lamp lights up during
the battery charging operation. The green indicator lamp lights up
once the battery is charged and the charging operation is complete.

" Plug the vehicle connector(4) into the power socket of your
vehicle.

" Click the battery(1) into the compartment so that the label is
on the top and towards the front.

BP07_822_1208EN 515
 Operation

Storing batteries Protective caps are provided for storing batteries.

Danger of fire
Bringing the terminals of the battery into contact with metal will
cause sparks, which may start a fire.
Before a battery can be stored or moved outside the battery com
partment or charging compartment, the terminals must be covered
with the protective cap provided.

1 2
BP07_822_1208EN 8

No. 0 Designation
1 Terminals
2 Protective cap

516 BP07_822_1208EN
 Operation

Cable remote control The boom movements which can be effected with the cable remote
control are black and white", i.e. the boom always moves at the
preselected speed when you move the joystick. The joystick must
always be pushed right to the stop to initiate movement.

Connecting To connect the cable remote control to the machine, proceed as

follows:

1 2 3 4 5 6

BP07_823_1105EN 1

No. 0 Designation
1 Remote control cable socket
2 Cable remote control
3 EMERGENCY STOP button
4 Control cabinet
5 Plug for the charger/receiver of the radio remote control
6 Remote control cable socket

BP07_823_1105EN 517
 Operation

Danger
When the cable remote controlis first connected to the control
cabinet, the machine may make unintended movements. Before
connecting the cable remote control, press the EMERGENCY STOP
button and set all control and monitoring devices on the cable
remote control to the 0" position.

" Pull the connector(5) out of the receiver for the radio remote
control.

" Plug the socket(6) for the remote control cable into this
connector (5) and secure the connection.

" Connect the socket(1) of the remote control cable to the cable
remote control(2) and ensure the connection is secure.

" Switch the Local control − 0 − Remote control" toggle switch

on the control cabinet(4) to Remote control".

518 BP07_823_1105EN
 Operation

Starting up You must proceed as follows to start operations with the machine
using cable remote control:

2
3 4

BP07_823_1105EN 2

No. 0 Designation
1 Cable remote control
2 EMERGENCY STOP button
3 Forward pumping − 0 − Reverse pumping" toggle switch
4 Horn + deactivate EMERGENCY STOP / Changeover"
toggle switch

" Unlock the EMERGENCY STOP button(2) by turning it.

" Operate the Horn + deactivate EMERGENCY STOP /

Changeover" toggle switch(4).
å The EMERGENCY STOP circuit is deactivated.
å The machine is ready for operation.

BP07_823_1105EN 519
 Operation

Starting up after To start the machine up again after having stopped the machine
EMERGENCY STOP using the EMERGENCY STOP button on the remote control, proceed
as follows:

" Unlock the EMERGENCY STOP button(2) by turning it.

" Operate the Horn + deactivate EMERGENCY STOP /

Changeover" toggle switch(4).
å The EMERGENCY STOP circuit is deactivated.

" Switch the pump off and then back on again using the
Forward pumping − 0 − Reverse pumping" toggle switch(3).
å The machine is ready for operation.

520 BP07_823_1105EN
 Operation

Boom speed You can use the Set boom speed" rotary switch to change the boom
speed.

The procedure for adjusting the speed of boom movement is as

follows:

1 2 3

BP07_823_1105EN 3

No. 0 Designation
1 Cable remote control
2 Boom functions − 0 − Support leg control" toggle switch
3 Set boom speed" rotary switch

Danger
The black and white" control style can lead to jerky movements and
significant bouncing of the boom, which represents a high risk of an
accident to the hoseman. Before starting pumping operations, set
the Set boom speed" rotary switch(3) to the 0" position.

" Switch the Boom functions − 0 − Support leg control" toggle

switch(2) on the cable remote control to Boom functions".

" Use the Set boom speed" rotary switch(3) to set the desired
boom speed by trial and error.

BP07_823_1105EN 521
 Operation

5.1.5 Acknowledge the The agitator is secured against unexpected restarts. When the
agitator safety cutout machine is set up, and when the agitator safety cutout is triggered,
itmust be acknowledged before the concrete pump can be switched
back on.

The agitator safety cutout is triggered in the following situations:

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

BP07_815_1105EN 1

No. 0 Designation
1 Acknowledge the agitator safety cutout

Danger
Risk of injury when the agitator is operating and the transfer tube is
switching. Before acknowledging the agitator safety cutout, check
that noone is in any danger.

" Activate the Acknowledge the agitator safety cutout" toggle

switch.

522 BP07_815_1105EN
 Operation

5.2 Centralized The centralized lubrication system integrated in your machine

lubrication system functions automatically, i.e.the machine is lubricated at fixed
programmed intervals.

1 2

5 4 3

BP07_861_1301EN 1

No. 0 Designation
1 Lubricant reservoir
2 Air bleeder
3 Grease gun
4 Filler nipple
5 Lubricant pump

BP07_861_1301EN 523
 Operation

5.2.1 Centralized The centralized lubrication system comprises a lubricant pump/

lubrication system grease gun, lubricant distributors, relief valves and supply lines.

Note
When carrying out any work on the centralized lubrication system,
you must proceed as follows:
 Check at regular intervals whether lubricant is actually emerging
atall lubrication points.
 Check the main lines and lines connected to lubrication points for
damage, and replace them if necessary.
 Pay particular attention to cleanliness. Dirt in the system causes
faults.

5.2.2 Filling the lubricant The lubricant reservoir may be filled up to the MAX" marking
reservoir through the filling nipple or from above through the filler opening.

Danger
Overfilling the lubricant reservoir can cause it to burst. When filling
the lubricant reservoir, DO NOT fill beyond the MAX" marking.

Caution
Risk of being pulled in or crushed on pumps where filling takes place
from the lubricant reservoir lid. Never reach into the open lubricant
reservoir when the lubricant pump is running.

524 BP07_861_1301EN
 Operation

Note
Note the following when filling the lubricant reservoir:
 Switch off the power supply before filling the reservoir from above.
 The air bleeder must not be closed when filling the lubricant reser
voir.
 Use only a grease listed in the lubricant recommendation table.
 The grease or oil must be free from impurities.
 Fill the reservoir up to the MAX" marking.
 Never pump the reservoir dry.

Grease gun The grease gun can be used to manually distribute grease to the
lubrication points.

Note
In many cases, the filler nipple of the lubricant reservoir is extended
with a hose and fastened to the truck superstructure so that the
lubricant reservoir can be filled more easily.

" Connect a grease gun(3) to the filler nipple(4) on the lubricant

reservoir(1).

" Open the air bleeder(2).

" Using the filler opening at the top, fill the lubricant reservoir(1)
with grease up to the MAX" marking.

" Close the air bleeder(2).

BP07_861_1301EN 525
 Operation

5.2.3 Additional You can cause an additional lubrication cycle to run if your machine
lubrication procedure is to be run under particularly heavy loading.

Note
An additional lubrication procedure is only possible if there is no fault
present. For this reason, pay attention to the centralized lubrication
system symbols on the control cabinet in the EGD. If a fault is
present or if a lubricant reservoir is empty, a centralized lubrication
system symbol lights up red and is also displayed in the HOME"
menu.

The red Centralized lubrication system" symbol is displayed per

manently until the fault is rectified. In Menu7" of the EGDRC on
theradio remote control, the Centralized lubrication system fault"
symbol is also displayed (see EGD and EGDRC" sections).

" You can start a manual lubrication procedure at the control

cabinet in the EGD by using the F4function button to select
and press the Centralized lubrication system" symbol.

526 BP07_861_1301EN
 Operation

5.3 Set–up site As a rule, the site management determines the set−up site for the
machine and prepares the site accordingly.

Note
However, it is the machine operator who takes the responsibility for
setting up the machine safely.

Inspect the proposed site carefully and reject the set−up site if you
have any doubts on safety grounds. Ask the site management about
the permitted ground pressure.

" Walk the approach route before you drive it. Ask for someone
to give you directions if you have to reverse.

" Maintain a safe distance from pits, slopes, trenches, etc., when
approaching the set−up site and when setting up.

" Ensure that there is clearance to extend the support legs.

" Check the clearance for extending the placing boom.

" Ensure that the set−up site is adequately ventilated. Exhaust

gases can be fatal.

Danger of poisoning
Vehicle exhaust gases contain constituents which can be lethal or
carcinogenic. Set the machine up at an adequately ventilated site or
vent the exhaust gases away from where you are working.

BP07_215_9807EN 527
 Operation

5.3.1 Space requirement

ÁÁÁ ÁÁÁ ÁÁ ÁÁ
ÁÁÁ ÁÁÁ ÁÁ ÁÁ
ÁÁÁ
ÁÁÁ ÁÁÁ
ÁÁÁ ÁÁ
ÁÁ ÁÁ
ÁÁ
ÁÁÁ ÁÁÁ ÁÁ ÁÁ
ÁÁÁ
ÁÁÁ ÁÁÁ
ÁÁÁ ÁÁ
ÁÁ ÁÁ
ÁÁ
ÁÁÁ
ÁÁÁ ÁÁÁ
ÁÁÁ ÁÁ
ÁÁ ÁÁ
ÁÁ
ÁÁÁ
ÁÁÁ ÁÁÁ
ÁÁÁ ÁÁ
ÁÁ ÁÁ
ÁÁ
12100801

The support legs must always be fully swung out and ex
tended

Normally supported

BP07_855_1212EN 1

1 Extent of forward supports = 6.3 m

2 Extent of rear supports = 7.3 m
3 Support−to−support distance = 7 m

528 BP07_855_1212EN
 Operation

One–Side–Support

BP07_855_1212EN 2

1 Extent of forward supports = 4.3 m

2 Extent of rear supports = 5.9 m
3 Support−to−support distance = 6 m

BP07_855_1212EN 529
 Operation

5.3.2 Danger zone

12100301

The danger zone when setting out the machine supports is the
zone in which the supports are swung out or extended.

Danger of crushing
There is a risk of crushing in the swingout and extension zone for
the supports.
You should therefore secure the danger zone.
Keep the danger zone under constant observation.
You must cease working immediately and press the EMERG
ENCYSTOP button if unauthorized persons enter the danger zone.

5.3.3 Lightning The set−up site must have sufficient lighting to ensure safe operation
of the machine.

" Ensure that the set−up site is adequately lit.

530 BP07_738_1209EN
 Operation

5.3.4 Minimum clearance The force transferred into the ground by each support diffuses
from pits through the ground in a conical pattern at an angle 45°. This imagin
ary cone must not exit through the wall of the pit.

45°
12100401

Minimum clearance a

" Maintain a minimum clearance of a" even if the pit is shallow

and the ground has good loadbearing capacity.

The minimum clearance a" for machines

− up to 12 t permissible gross weight, is 1 m;
− over 12 t permissible gross weight, is 2 m.

BP07_738_1209EN 531
 Operation

5.3.5 Safe clearance

from pits

Ay2 T Ay1 T

ÇÇÇÇÇÇÇÇ
ÇÇÇÇÇÇÇÇ
ÇÇÇÇÇÇÇÇ T

ÇÇÇÇÇÇÇÇÇÇÇÇ 12100402

Safe clearance A

" Maintain the additional safe clearance A.

The safe clearance A

− for loose, backfilled ground is A y 2 pit depth T,
− for compact, non−friable ground is A y 1 pit depth T.

5.3.6 Supporting ground

22102802

No voids or other irregularities of the ground under the support

feet

532 BP07_738_1209EN
 Operation

22102803

Only on level supporting ground

Caution
Do not bridge voids or other ground irregularities with support plates
or timber blocks. These may break if a point load is applied to them.
This means that the machine will not have the necessary stability.
Ensure that the supporting ground is level.

BP07_738_1209EN 533
 Operation

5.3.7 Support area The machine must be supported in accordance with the corner bear
ing loads of the machine and the loadbearing capacity of the sup
porting ground (permissible ground pressure). You will have to ex
tend the support area if the permissible ground pressure for a soil
type is exceeded.

Danger
If you support the machine without support plates, there is a risk that
the machine will tip over. If there is heavy rain, for example, the
ground conditions can suddenly change. Therefore, at the very least,
you must always place the Putzmeister support plates under the foot
plates in order to increase the support area.

Support plate

BP07_738_1209EN 1

Always use Putzmeister support plates

534 BP07_738_1209EN
 Operation

Corner bearing load

BP07_739_0912EN 1

The corner bearing load is specified on each support leg

" Ask the site management about the permissible ground pres
sure.

" Calculate whether the support area provided is adequate.

Note
The support area is adequate if the maximum possible ground pres
sure is less than the permissible ground pressure. The maximum
possible ground pressure is calculated as follows:

Machine corner bearing load

Max possible ground pressure =
Max.
Support area

Calculation example Permissible ground pressure, 600 kN/m2

as stated by the site management

Support area (= support plate area) 0.36 m2

Machine corner bearing load 160 kN

å maximum possible ground pressure 444 kN/m2

In this example, it is sufficient to place Putzmeister support plates

(60cmx60cm) beneath the support feet.

BP07_739_0912EN 535
 Operation

Length of the timber The table below shows the minimum length of the timber blocks re
blocks required quired.

Danger
Always use 4timber blocks with a cross section of 15cmx15cm
each and of the length shown in the table. Place the 4timber blocks
together beneath the support plate as shown. The support plate and
the timber blocks must always be free from grease, oil, ice, etc., as
otherwise the support leg could slip off.

The timber blocks must meet the following minimum requirements:

 S10TS sorting in accordance with EN14081
 Strength class C24 in accordance with EN338
 Pressure−treated

12100502

536 BP07_739_0912EN
 Operation

Corner bearing load

in kN (see support leg) 50 75 100 125 150 175 200 225 250 275 300 325 350 375 400

Permissible
ground pressure kN/ Timber block lengths in cm
m2
Undisturbed soil 100
84 125 167 209 250
Supporting
pp gg
ground is not
Asphalt 200 suitable for support
84 105 125 146 167
(minimum 20 cm thick)
Hardcore 250
84 100 117 134 150 167
(compacted)
Clay, coarse clay 300
84 98 112 125 139 153 167
(firm)
Mixed stone 350
84 96 108 119 131 143 155 167
(firm)
Layered gravel 400 With Putzmeister
84 94 105 115 125 136 146 157 167
(firm) support plates
500
75 84 92 100 109 117 125 134
750
73 78 84 89
Rock 1000
(fractured, weathered)

Conversion: 100 kN/m2 = 1 daN/cm2

Note
You should use the next higher value if the corner bearing load is not
exactly the same as the value specified in the table (e.g.actual
corner bearing load of the machine = 180kN;
you must take the timber block length from the 200kN column from
the table).

BP07_739_0912EN 537
 Operation

Example 1
Corner bearing load
in kN (see support leg) 50 75 100 125 150 175 200

Permissible
ground pressure kN/ Timber block lengths in cm
m2
Undisturbed soil 100
84 125 167 209 250
Asphalt 200
84 105 125 146 167
(minimum 20 cm thick)
Hardcore 250
84 100 117 134
(compacted)
Clay, coarse clay 300
84 98 112
(firm)
Mixed stone 350
84 96
(firm)
Layered gravel 400 With Putzmeister
84
(firm) support plates
500

Soil type: firmly layered gravel

Permissible ground pressure 400 kN/m2
Machine corner bearing load 150 kN
Timber block length not required
In this example it is sufficient to place Putzmeister support plates
(60cmx60cm) beneath the support feet.

538 BP07_739_0912EN
 Operation

Example 2
Corner bearing load
in kN (see support leg) 50 75 100 125 150 175 200

Permissible
ground pressure kN/ Timber block lengths in cm
m2
Undisturbed soil 100
84 125 167 209 250
Asphalt 200
84 105 125 146 167
(minimum 20 cm thick)
Hardcore 250
84 100 117 134
(compacted)
Clay, coarse clay 300
84 98 112
(firm)
Mixed stone 350
84 96
(firm)
Layered gravel 400 With Putzmeister
84
(firm) support plates
500

Soil type: compacted hardcore

Permissible ground pressure 250 kN/m2
Machine corner bearing load 150 kN
Timber block length at least 100cm
In this example you must place 4timber blocks with a cross−sec
tion of 15cmx15cm and a length of at least 100cm beneath the
support feet in addition to the Putzmeister support plates
(60cmx60cm).

BP07_739_0912EN 539
 Operation

5.4 Supporting the You must have read the safety regulations and have completed the
machine operations for starting up the machine before you begin setting out
the machine supports.

Danger
There is a risk of injury due to unexpected movement of the support
legs.
The machine supports may only be used under the following
conditions:
 the pump drive engine is running;
 the power takeoff is engaged (i.e.the machine is set to pumping
operations);
 the Support" function has been selected using the remote control
or on the control block.
It is absolutely forbidden to move the supports manually
(mechanically).

12101600

Do not move the hydraulic support legs manually

540 BP07_303_1109EN
 Operation

Note
You must apply the parking brake before you engage the power
takeoff if your truck engine is equipped with electronic diesel control
(EDC). Otherwise you will not be able to increase the engine speed
during pumping operations. This is also the case if you release the
parking brake and apply it again while the power takeoff is
engaged.

" Drive the machine to the setup site you have inspected.

" Apply the parking brake.

" Engage the power takeoff.

5.4.1 Working area

BP07_303_1109EN 1

The working area is the area in which work is

carried out with or on the machine.

Danger
Persons who remain in the working area without authorization can be
injured.
You should therefore secure the working area. Keep the working area
under constant observation.
You must cease working immediately and press the EMERGENCY
STOP button if unauthorized persons enter the working area.

BP07_303_1109EN 541
 Operation

5.4.2 Remote control

2.
1.

BP07_303_1109EN 2

Preselection switch

You must first switch on the support functions before you can
support the machine.

" Switch on the remote control.

" Switch the toggle switch on the remote control to

SupportsOn".

Note
First pull up the toggle switch(1.) and then press it towards the
symbol(2.).

542 BP07_303_1109EN
 Operation

5.4.3 Interlock

2.
1.
BP07_303_1109EN 3

Snaplock

You must unlock the support legs before you are able to extend them
or swing them out.

" Pull out the spring pin(1.).

" Open the snaplock using the lever(2.).

Danger
On multiple telescoping support legs, the snaplock only locks the
outer support leg box and not the inner support leg. You should
therefore check after extending or retracting the support legs that
both the support leg box and the support leg are fully extended/
retracted.

BP07_303_1109EN 543
 Operation

Note
Extendable support legs are automatically locked by the snaplock
once the support leg is fully extended.
Replace the spring pin once the legs are locked. The snaplock
cannot now be opened unintentionally and the support leg remains
locked in the end position.

The snaplock has no function once swingout support legs have

been swung out. Do not replace the spring pin; in this way the
support legs will be locked automatically when they are swung back.

Before driving off, make sure that all the snaplocks are secured by a
spring pin.

544 BP07_303_1109EN
 Operation

5.4.4 Danger zone

12100300

The danger zone when setting out the machine supports is the
zone in which the support legs are swung out or extended.

Danger of crushing
There is a risk of crushing in the swingout and extension zone for
the supports.
You should therefore secure the danger zone. Keep the danger zone
under constant observation.
You must halt work immediately and press the EMERGENCYSTOP
button if anyone enters the danger zone.

Uncontrolled movements of the support legs increase the risk of

accident. They are possible if:
 the hydraulic system has not been carefully bled;
 lines or threaded unions are leaking;
 there is insufficient hydraulic fluid in the reservoir;
 the preselection switch is defective or dirty.

In this case, the support legs may move as soon as the preselection
switch is actuated.
Halt work immediately. You can continue working only after the
causes have been remedied and perfect functioning of the machine
is ensured.

BP07_303_1109EN 545
 Operation

5.4.5 Stability The gross weight of the machine determines the location of the
centre of gravity. The positions of the support legs define the tilting
edges. So that the machine is stable, the centre of gravity must
always be within the tilting edges.

BP07_303_1109EN 4

No. 0 Designation
1 Tilting edges
2 Possible centreofgravity line with a 360°rotation of the
placing boom

Danger
If the machine is not correctly supported, there is a risk to life, as the
machine may tip over.

To ensure stability, you must put the machine into normal operation,
 extend/swing out the support legs as far as they will go
 and lift the machine clear of the ground.

Thanks to our product observations, we have determined that during

operation, it is not rare to find the rear wheels remaining on the
ground. This allows you to achieve smoother pumping and a lower
fillheight, but lessthanperfect stability during normal operation.
Donot swing the arm assembly towards the rear, as this does not
ensure stability.

546 BP07_303_1109EN
 Operation

5.4.6 Spirit level

5d
3d

1
32100101

1 Permissible range of deviation from the horizontal

Caution
You must only execute the support functions one at a time.
Observe the spirit level when extending the support feet. The truck
must stand level. Stability is compromised at a deviation from the
horizontal of more than 3_.

BP07_303_1109EN 547
 Operation

5.4.7 Forward support legs

1 2

BP07_856_1212EN 1

1 Preselect lever
2 Extend and retract forward support leg

Proceed as follows to extend the forward support legs:

" Press the preselect lever(1) downwards to activate the func

tion.

" Pull the lever(2) upwards to extend the forward support leg.
After you have fully extended the support leg, release the
lever(2).

" Release the preselect lever(1). It automatically returns to the

0position.

" Do the same on the other side of the truck.

548 BP07_856_1212EN
 Operation

5.4.8 Rear support legs

1 2

BP07_856_1212EN 2

1 Preselect lever
2 Swing rear support leg out and in

Proceed as follows to swing out the rear support legs:

" Press the preselect lever(1) downwards to activate the func

tion.

" To swing out the rear support leg, pull the lever(2) upwards.
After you have fully swung out the support leg, release the
lever(2).

" Release the preselect lever(1). It automatically returns to the

0position.

" Do the same on the other side of the truck.

BP07_856_1212EN 549
 Operation

5.4.9 Forward support feet

1 2

BP07_856_1212EN 3

1 Preselect lever
2 Extend and retract the forward support foot

Proceed as follows to lower the forward support feet:

" Press the preselect lever(1) downwards to activate the func

tion.

" To extend the forward support foot, pull the lever(2) upwards.
After you have fully extended the support foot, release the
lever(2).

" Release the preselect lever(1). It automatically returns to the

0position.

" Do the same on the other side of the truck.

550 BP07_856_1212EN
 Operation

5.4.10 Rear support feet

1 2

BP07_856_1212EN 4

1 Preselect lever
2 Raise and lower rear support foot

Proceed as follows to lower the rear support feet:

" Press the preselect lever(1) downwards to activate the func

tion.

" Pull the lever(2) upwards to extend the rear support foot. After
you have fully extended the support foot, release the lever(2).

" Release the preselect lever(1). It automatically returns to the

0position.

" Do the same on the other side of the truck.

BP07_856_1212EN 551
 Operation

5.4.11 Switching off the

support function

BP07_059_0805EN 1

Preselection switch

The support function must be switched off before operations can

continue.

" Set the toggle switch on the remote control back to the boom
function" position.

Note
Continue to observe the spirit level and the supports whilst operating
the pump. The machine must always be standing level and firmly on
the ground.

552 BP07_059_0805EN
 Operation

5.5 Special case of Busy traffic conditions and space problems on construction sites
“One–Side–Support“ sometimes do not allow the support legs to be swung out or ex
tended fully. In special circumstances of this nature, you may set up
the machine with One−Side−Support" as described below.

Danger
This arrangement of supports should be the exception. Wherever
possible, you must set out the machine’s supports such that all sup
port legs are swung out and extended to their normal end position.

Follow the instructions precisely when using One−Side−Support"

and work with great care. As a precaution, use timber blocks that are
greater than necessary beneath the support plates. This will prevent
the stability being additionally endangered by a support foot sinking.

Maintain the necessary distance from pits, slopes and similar when
using One−Side−Support.

BP07_158_0109EN 553
 Operation

5.5.1 Supporting the

machine

BP07_158_0109EN 1

1 Construction site

" Drive the machine up to the proposed site of operations so that

it is parked approximately at right−angles to the construction
site.

554 BP07_158_0109EN
 Operation

Danger
The swinging support legs on the working side must be fully swung
out and extended to the normal end position.

BP07_158_0109EN 2

Supports on the working side

1 Construction site

" First support the machine on the working side.

BP07_158_0109EN 555
 Operation

Note
The boom will not be shown in the next two illustrations to assist you
in identifying the subsequent operations.

BP07_158_0109EN 3

Swing out the rear support leg

1 Construction site

" Swing the rear support leg on the restricted side out at least
one metre.

556 BP07_158_0109EN
 Operation

Danger
The forward support leg must be either fully extended or fully
retracted. Intermediate positions are not permitted, as they can lead
to significant damage to the machine and can impair stability.

You should therefore leave the forward support leg on the restricted
side retracted when you are using One−Side−Support to set the
machine up.

BP07_158_0109EN 4

Lowering the forward support foot

1 Construction site

" Place support blocks and timber blocks beneath the support
feet on the restricted side.

" Support the machine by lowering the support feet.

BP07_158_0109EN 557
 Operation

5.5.2 Restricted working

range
120_

BP07_158_0109EN 5

1 Working range in One−Side−Support

Note
The working range when using One−Side−Support is around 120_,
calculated from the transport position of the boom.

558 BP07_158_0109EN
 Operation

5.5.3 Switching off the

support function

BP07_059_0805EN 1

Preselection switch

The support function must be switched off before operations can

continue.

" Set the toggle switch on the remote control back to the boom
function" position.

Note
Continue to observe the spirit level and the supports whilst operating
the pump. The machine must always be standing level and firmly on
the ground.

BP07_059_0805EN 559
 Operation

5.6 Function checks You should check the following functions before you begin using
themachine on the construction site.

5.6.1 Pump functions The fundamental prerequisite for problemfree use is a fully
functional pump.

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

Magnetic switches

BP07_595_0912EN 1

Checking the magnetic switches

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

560 BP07_595_0912EN
 Operation

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

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

" Set the engine to maximum speed.

" Set the maximum pumping rate.

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

" Measure the stroke time over a period of ten single strokes.

The value measured, divided by ten, must match the data in the test
reading.

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

BP07_595_0912EN 561
 Operation

5.6.2 Filter functions There are a number of filters in the machine’s hydraulic system.
Thevacuum return flow filter is monitored by sensors. The display
shows whether the filter element needs to be replaced.

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

Note
Only the section return flow filter is monitored. Once the filter element
for the vacuum return flow filter needs replacing, the other filter ele
ments must also be replaced.

Vacuum return flow

filter warning
indicator

1
BP07_817_1105EN 1

No. 0 Designation
1 Vacuum return flow filter warning indicator

562 BP07_817_1105EN
 Operation

Note
The warning indicator for the vacuum return flow filter turns red when
the oil temperature exceeds 25_C and at the maximum engine
speed; the filter element must be replaced.

Danger
Risk of injury due to faults with the hydraulic fluid circuit. Unfiltered
hydraulic fluid causes faults with hydraulic components, leading the
machine to move unexpectedly. Ensure the machine is not run with
unfiltered hydraulic fluid.

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

BP07_817_1105EN 563
 Operation

5.6.3 EMERGENCY STOP It is only possible to intervene rapidly in the event of danger if all the
function EMERGENCY STOP buttons are functioning.

Caution
The machine is no longer operating safely if one of the EMERGENCY
STOP buttons is defective, as you will no longer be able to switch the
machine off quickly enough if danger threatens.
You must therefore inspect the function of the EMERGENCY STOP
buttons and the lever position for the boom valves (see Function
check on the boom control block") before starting work each time.

Danger
The machine is only switched off electrically when the EMERGENCY
STOP button is pressed. Although this causes all the electrically
actuated hydraulic valves to be switched off, an unexpected sinking
of the boom caused by leaks in the hydraulic system, for instance,
cannot be prevented in this way.

In no event should you first press the EMERGENCY STOP button if

the boom starts unexpected movements. Should you do this you will
have no ability to counteract the movement.

564 BP07_830_1112EN
 Operation

EMERGENCY STOP
button

10500200

Press − lock EMERGENCY STOP

Turn − unlock EMERGENCY STOP

" Switch the pump on.

" Operate a boom function.

" Press one of the EMERGENCY STOP buttons.

The pump and the boom must come to a halt immediately.

" Check all EMERGENCY STOP buttons on the machine and on

the remote control in the same way.

BP07_830_1112EN 565
 Operation

5.6.4 Function check on the You may only operate the machine if the boom control block is fully
boom control block functional.

" Switch on the radio or cable remote control.

" Operate the boom control levers briefly several times while
observing the levers on the boom control block.
å The lever for the boom valve operated and the lever for the
operating mode selector valve must move each time.

Note
As soon as you release the boom control levers using the remote
control unit, the levers for the boom armvalves previously actuated
and for the operating mode selector valve must return to the central
position (zeroposition).

The reactions of the operating mode selector valve on the boom

control block are delayed by some 3seconds if you use the cable
remote control.

566 BP07_818_1105EN
 Operation

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

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

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

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

You must stop work if you open the grille, but

 the agitator continues to run, or
 the transfer tube continues to switch over, or
 the concrete pump does not run to its end position.

BP07_816_1111EN 567
 Operation

1 2 3

BP07_816_1111EN 1

No. 0 Designation
1 Reading head (on the hopper − example illustration)
2 LED, green and red
3 Transponder (in the grille)

" Open the grille with the concrete pump running.

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

Danger
Risk of injury when the agitator is operating and the transfer tube is
switching. Before acknowledging the agitator safety cutout, check
that noone is in any danger.

Note
You must acknowledge the agitator safety cutout and switch the con
crete pump off and back on again to restart it.

568 BP07_816_1111EN
 Operation

5.7 Boom movements Before you unfold the placing boom you must have read the safety
regulations and completed the operations to set up the machine.

You may only unfold the placing boom once you have set the ma
chine up properly. Comply with the safety regulations of the country
in which you are using the machine in every case.

Prohibited activities

BP07_005_1201EN 1

Prohibited

Danger
Avoid the following actions. They overload the placing boom and will
lead to damage and jeopardize persons:
 Lifting and transporting loads;
 Allowing the placing boom to strike an obstacle;
 Pushing with the placing boom, in order to move an obstacle out
of the way, for instance;
 Tearing away a trapped end hose by force.

BP07_005_1201EN 569
 Operation

5.7.1 Restrictions on use Extreme weather conditions, such as gales, storms or low tempera
tures restrict the use of the boom, or can even make its use imposs
ible.

Bad weather and Shift the placing boom to the rest position in the event of storms and
storms bad weather.
− Booms with a vertical reach of 42m or more (M42 and larger)
may only be operated in wind forces up to7(wind
speed61km/h=17m/s).
− Booms with a vertical reach of less than 42m (< M42) may only
be operated in wind forces up to8(wind
speed74km/h=20m/s).

Wind speeds in accordance with the Beaufort scale are average

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

Danger
There is a risk of fatal injury in the event of a lightning strike. The ma
chine and the surrounding area will be charged with electricity.
Earthing the machine does not reduce this risk. You should therefore
fold in the placing boom if there is a risk of lightning strike.

Tower cranes on construction sites generally have wind speed

measuring equipment, so that you can ask about the wind speed at
any time. If no wind speed measuring equipment is available, you
can ask the nearest meteorological office what the wind speed is, or
estimate the wind speed using the following rule of thumb.
− In winds of force 7 and greater, green leaves break from trees and
inconvenience is felt when walking against the wind.
− In winds of force8 and greater, small branches break from trees
and walking outside is significantly impeded.

570 BP07_005_1201EN
 Operation

Cold weather The placing boom must not be used in temperatures below minus
15_C (+5_F). There is a danger of damage to the steel (brittle frac
ture) and the seals throughout the system at such extreme minus
temperatures.

In addition, such minus temperatures should be considered the real

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

5.7.2 Danger zone

22000500

The danger zone when working with the boom is the zone over
which the boom is slewed.

Falling items
There is a risk of injury from parts of the delivery line falling beneath
the slewing circle of the placing boom. There is a risk of injury from
falling concrete beneath the end hose.
You should therefore secure the danger zone. Keep the danger zone
under constant observation.
You must cease working immediately and press the EMERG
ENCYSTOP button if unauthorized persons enter the danger zone.

BP07_005_1201EN 571
 Operation

High–voltage lines

BP07_005_1201EN 2

Caution in the vicinity of high−voltage lines

Danger
There is a risk of fatal injury if high−voltage lines are touched. The
machine and the surrounding area will be charged with electricity. A
spark can jump across from high−voltage lines even if you just ap
proach them and this will energize the machine and the surrounding
area. You must therefore always maintain the specified safe clear
ance.

Rated voltage [V] Safe clearance [m]

up to 1 kV 1.0

1 kV to 110 kV 3.0

110 kV to 220 kV 4.0

220 kV to 380 kV 5.0

unknown rated voltage 5.0

572 BP07_005_1201EN
 Operation

Overlapping working
ranges

BP07_005_1201EN 3

Beware of overlaps

Caution
Take note of the working ranges of other construction plant (e.g.
cranes, other concrete placing booms, etc).

Signalling boom
movements

BP07_005_1201EN 4

Sound the horn first, then move

Note
Move the placing boom with cautious operation of the controls.
Maintain visual contact with the placing site.
Warn by sounding the horn before you move the boom.

BP07_005_1201EN 573
 Operation

Hand signals

10000331

See the Hand signal for boom and pumping operations"

chapter for hand signals

Danger
Move the placing boom only if you can see all of the working range.
If this is not possible, you must only move the placing boom in re
sponse to signals from a signaller.
Agree unambiguous hand signals with the signallers.

574 BP07_005_1201EN
 Operation

5.7.3 Spontaneous retrac- During operation, the hydraulic fluid can heat up to a temperature of
tion of the boom 60−70 °C.
cylinders and support When the hydraulic fluid cools, its volume reduces as cold hydraulic
cylinders fluid has a smaller volume than hot hydraulic fluid. This causes the
boom cylinders, swing−out cylinders, telescopic cylinders and sup
port cylinders to retract slightly. The boom and the machine may
lower, the telescopic and swinging support legs may retract or swing
in.

Danger
Retraction of the swing−out cylinders, telescopic cylinders and sup
port cylinders may cause the machine to tip over. This causes a
danger to life and limb to persons who remain in the area of the
boom. You must keep the supports under constant observation whilst
the machine is in operation. You may have to readjust the swing−out
cylinders, telescopic cylinders and support cylinders.

Caution
The boom can sink during lengthy pauses in work due to cooling of
the hydraulic fluid. Consequently, the boom may be damaged or
other objects may be damaged by the boom. For this reason, you
should never leave the boom unattended in the unfolded position
during breaks in working.

BP07_005_1201EN 575
 Operation

Loss of volume

BP07_005_1201EN 5

Note
The size of the change in volume in a hydraulic cylinder depends on
the extent to which the hydraulic cylinder has been extended and
the magnitude of the temperature difference in the hydraulic fluid.

576 BP07_005_1201EN
 Operation

5.7.4 Uncontrolled boom The following defects may be the cause of uncontrolled boom move
movements ments:
− Malfunction in the remote control circuit
− Malfunctions on the boom control block
− Lines, threaded unions or boom cylinders leaking
− Defective mono−isolator on the boom cylinder
− Hydraulic system not carefully bled
− Insufficient hydraulic fluid in the reservoir
− Cooling of the hydraulic fluid

In this case, the boom may move as soon as the remote control is
switched on. Halt work immediately. You can continue working only
after the causes have been remedied and perfect functioning of the
machine is ensured.

Note
Whatever the reason for the uncontrolled movements of the boom,
you must halt the work on site and have the cause of the breakdown
determined and rectified by qualified personnel.

Danger
In no event should you first press the EMERGENCY STOP button if
the boom starts unexpected movements. Should you do this you will
have no ability to counteract the movement.

BP07_005_1201EN 577
 Operation

Countermeasures You must proceed as follows if the boom starts uncontrolled move
ment:

" Counter the uncontrolled movement immediately and attempt

to steer the boom out of the danger zone and bring it to rest
under control.

If the uncontrolled boom movement continues, despite countermea

sures:

" Press the EMERGENCY STOP button.

Note
Repeated practice is required to ensure that it will be possible to im
plement the measures described above in an emergency.

578 BP07_005_1201EN
 Operation

5.8 Hand signals for Pump operators and persons guiding them must agree unambigu
boom and pumping ous hand signals before commencing work. Suggestions for the
operations most important hand signals are made in this chapter. They are
based on DIN24081, DIN 33409 and guideline RI/08.90/2 issued by
the German Construction Employers’ Liability Insurance Association,
amongst other guidelines. The direction of movement is specified
from the machine operator’s direction of view.

EMERGENCY STOP Extend both arms outwards

and move up and down quickly.

10000308

Stop Extend both arms out

totheside.

10000306

Slow Place a fist on the helmet.

10000307

BP07_006_0904EN 579
 Operation

Slew boom to the left One arm points in the

slewingdirection.

10000309

Slew boom to One arm points in the

the right slewingdirection.

10000310

Arm 1 up One arm hangs vertically

downwards. The other arm
points upwards with the thumb.

10000311

Arm 1 down One arm hangs vertically

downwards. The other arm
points downwards with the
thumb.

10000312

580 BP07_006_0904EN
 Operation

Arm 2 up One arm points downwards at

an angle. The other arm points
upwards with the thumb.

10000313

Arm 2 down One arm points downwards at

an angle. The other arm points
downwards with the thumb.

10000314

Arm 3 up One arm points horizontally to

the side. The other arm points
upwards with the thumb.

10000315

Arm 3 down One arm points horizontally to

the side. The other arm points
downwards with the thumb.

10000316

BP07_006_0904EN 581
 Operation

Arm 4 up One arm points upwards at an

angle. The other arm points
upwards with the thumb.

10000317

Arm 4 down One arm points upwards at an

angle. The other arm points
downwards with the thumb.

10000318

Arm 5 up One arm points vertically up

wards. The other arm points
upwards with the thumb.

10000319

Arm 5 down One arm points vertically up

wards. The other arm points
downwards with the thumb.

10000320

582 BP07_006_0904EN
 Operation

End hose forwards Move both crooked arms

forwards and backwards.
Thepalms of the hands face
inwards towards the person
giving directions.

10000321

End hose back Move both crooked arms

forwards and backwards.
Thepalms of the hands face
away from the person giving
directions.

10000322

End hose to the left Both arms point in the direction

of movement for the end hose.

10000323

End hose to the right Both arms point in the direction

of movement for the end hose.

10000324

BP07_006_0904EN 583
 Operation

End hose up Move both crooked arms up

wards and downwards with the
thumbs pointing upwards.

10000325

End hose down Both arms move up and down.

Both index fingers point down
wards.

10000326

Increase output/ The thumb of one hand points

Start pumping upwards. The palm of the other
hand is held over it.

10000327

Reduce output The thumb of one hand points

downwards. The palm of the
other hand is held under it.

10000328

584 BP07_006_0904EN
 Operation

Reverse pumping The crooked elbow of one arm

points downwards into the palm
of the other hand.

10000329

Stop pumping Grip both hands together over

the head.

10000330

BP07_006_0904EN 585
 Operation

5.9 Unfolding Follow the sequence specified for unfolding the 5RZboom. The
the 5 RZ boom boom must be folded in the reverse sequence.

Note
You must unfold the armassembly to the side of the truck to maintain
the lowest possible unfolding height.

Caution
Always observe the specified sequence for folding and unfolding the
boom. Failure to comply with the sequence may allow the crank lever
in the Dhinge to compress the delivery line, adjacent hydraulic cylin
ders or other components.

Take extreme care when unfolding the boom. Look out for any ob
stacles which may obstruct the boom as it is being unfolded.

You should further note that the end hose (depending on the ma
chine’s equipment) is positioned loosely in the end hose brackets
and hangs down freely when the boom is being folded in and out.

586 BP07_857_1212EN
 Operation

5.9.1 Unfolding sequence

75°

BP07_857_1212EN 1

Raising arm1

" Raise arm1 through approximately 75°.

BP07_857_1212EN 2

Slewing the placing boom

" Slew the placing boom in the required direction.

BP07_857_1212EN 587
 Operation

Caution
If the machine is equipped with end hose brackets without locking
mechanisms, you will require more clearance beneath the arm as
sembly when this is being unfolded to ensure that the end hose does
not scrape along the ground.

BP07_857_1212EN 3

Unfolding arm2

" Unfold arm2 in such a way that you can then unfold the re
maining arms without any problems.

BP07_857_1212EN 4

Unfolding arm3

" Unfold arm3.

588 BP07_857_1212EN
 Operation

Caution
Before you unfold arm4, you must unfold arm5 approximately 15_,
so that the boom tip is approximately 1m away from the Dhinge
(hinge between arm3 and arm4). The crank lever on the Dhinge
will press against the elbow at the boom tip if you do not follow this
instruction.

15°

BP07_857_1212EN 5

Unfolding arm5

" Unfold arm5 approximately 15_.

BP07_857_1212EN 589
 Operation

End hose brackets

without locking
mechanisms

BP07_857_1212EN 6

Unfolding arm4

" Unfold arm4.

BP07_857_1212EN 7

Unfolding arm5

" Unfold arm5.

590 BP07_857_1212EN
 Operation

End hose brackets

with locking
mechanisms

BP07_857_1212EN 8

Unfolding arm4

" Unfold arm4.

Note
If the machine is equipped with end hose brackets with locking
mechanisms, you must unfold arm4 further to enable you to release
the end hose after arm5 is unfolded.

BP07_857_1212EN 9

Unfolding arm5

" Unfold arm5 far enough to allow you to unlock the end hose.

BP07_857_1212EN 591
 Operation

End hose

12500401

Unlocking the end hose

" Unlock the end hose by pulling the two locking levers down
wards.

BP07_857_1212EN 10

Unlocking the end hose

592 BP07_857_1212EN
 Operation

5.9.2 Impermissible
working range

BP07_857_1212EN 11

1 Zone in which work with the end hose is not permitted

Caution
The end hose must not be shifted behind the vertical of the boom.

BP07_857_1212EN 593
 Operation

5.10 Unfolding the boom If you have set up the machine using One−Side−Support you must
when using One– only unfold the boom as described below.
Side–Support
Danger
The working range must have been preselected using the OSS key
switch on the control cabinet when the boom is unfolded using One−
Side−Support, as otherwise the safe working range of 120_is not se
cured. The consequence of this could be that you would be able to
slew the boom into the prohibited working range and the machine
would tip over.

Once you have preselected the working range, you must take the
key from the OSS keyswitch and keep it on your person, to ensure
that no unauthorized person can change the preselection.

Note
The working range in the example described below is on the right−
hand side of the truck (passenger side).

594 BP07_858_1212EN
 Operation

BP07_858_1212EN 1

" Turn the OSS keyswitch on the control cabinet towards the re
quired working range.
å The marking on the OSS keyswitch points towards the sym
bol corresponding to your support.
å The green indicator lamp for the selected working range on
the control cabinet lights up.
å The green flashing OSS−lamp for the selected working
range on the boom pedestal lights up.

" Remove the key from the OSS keyswitch and put it away.

Danger
The indicator lamp on the control cabinet and the flashing beacon on
the boom pedestal lighting up the wrong way round is an indication
of a fault in the electrical system. In this event you must not use the
OSS facility.

BP07_858_1212EN 595
 Operation

Caution
Always observe the specified sequence for folding and unfolding the
boom. Failure to comply with the sequence may allow the crank lever
in the Dhinge to compress the delivery line, adjacent hydraulic cylin
ders or other components.

You should further note that the end hose (depending on the ma
chine’s equipment) is positioned loosely in the end hose brackets
and hangs down freely when the boom is being folded in and out.

90°

BP07_858_1212EN 2

" Raise the boom to the vertical.

596 BP07_858_1212EN
 Operation

Danger
It may be necessary for you first to slew the boom through the pro
hibited working range. This will depend on how the boom was previ
ously positioned.

Only slew the boom through the prohibited working range when it is
pointing vertically upwards.

BP07_858_1212EN 3

" Slew the boom into the desired working range.

BP07_858_1212EN 597
 Operation

Checking the working range restriction

BP07_858_1212EN 4

Note
Once you have slewed the boom into the desired working range, you
will only be able to slew the boom to the boundary of the working
range. The slewing movement will be stopped by limit switches when
the boom is slewed to the boundary. You will then only be able to
slew the boom in the opposite direction.

Danger
The limit switches for the working range restriction must be checked
before each job.

You must cease OSS working and set out the machine supports fully
if you should determine in your inspection of the working range re
striction that the limit switches are not operating perfectly.

" Slew the boom fully to the left and fully to the right until the
slewing movement is stopped automatically in each case.

598 BP07_858_1212EN
 Operation

Switch off the flashing

OSS–lamp

BP07_858_1212EN 5

" On the control cabinet you can switch off the OSS−lamp up on
the boom pedestal after testing the limit switches.

" Continue unfolding the arm assembly, as described in the Un

folding the 5RZboom" section.

BP07_858_1212EN 599
 Operation

5.11 Filling and draining Check the water fill level and the water cleanliness in the water box
the water box daily. As required, you must either empty or fill the water box. The
following section describes how to drain and fill the water box.

Caution
Risk of the concrete pump overheating if the fill level in the water box
is too low.
Check the water fill level in water box regularly. As required, fill the
water box with cold and clean water in order to prevent the concrete
pump from overheating and other subsequent damage.

When emptying the water box, check the condition of the water −
particularly that it is clean.
 A chalky white colour is a sign of cement in the water.
This is an indication of damaged delivery pistons.
 An unusual amount of hydraulic fluid in the water indicates that the
drive cylinders are leaking.

Damage to the delivery pistons or drive cylinders must be rectified

immediately. Putzmeister accepts no warranty claims for damage to
the machine resulting from failure to properly observe the mainten
ance regulations.

5100 BP07_825_1111EN
 Operation

2 3
7

BP07_825_1111EN 1

No. 0 Designation
1 Plan view of the machine
2 Water tank
3 Water box fill cock
4 Lid with seal
5 Grille
6 Water outlet
7 Water box

BP07_825_1111EN 5101
 Operation

Filling the water box Proceed as follows to fill the water box:

" Remove the lid (4) of the water box.

" Make sure that water outlet(6) is closed.

" Open the cock(3) to fill the water box until water starts to flow
out of the water box.

" Close the cock(3) to fill the water box.

" Refit the lid(4) of the water box.

Draining the water box Proceed as follows to drain the water box:

" Remove the lid (4) of the water box.

" Pull the water outlet(6) upwards.

å The water drains out.

" Slowly move the delivery pistons until the water has escaped
from the delivery cylinders.

" Refit the lid(4) of the water box.

5102 BP07_825_1111EN
 Operation

5.12 Pumping operations You must carry out the following procedures before you start to
pump:
− Set the machine up for work properly (see Setting up" section).
− Set the machine supports out properly (see Supporting the ma
chine" section).
− Carry out all necessary function checks (see Function checks"
section).
− Unfold the boom to the desired working position (see Unfolding
the placing boom" section).

5.12.1 Dangers Dangers to the life and limb of site personnel can arise at many
points during pumping operations. You can minimize these dangers
by observing the following notes.

Danger
The machine is at risk of toppling over if the gross weight of all fit
tings (e.g. including the squeeze valve) at the boom tip including
concrete filling exceeds the maximum loadbearing capacity of the
placing boom.

The gross weight of all fittings at the boom tip including concrete fill
ing must not exceed the maximum loadbearing capacity of the plac
ing boom.
As a result, you must only use the end hoses specified by the manu
facturer in your machine documentation.

BP07_320_1111EN 5103
 Operation

Danger
There is a risk of injury in the area around the end hose if the end
hose strikes out when starting to pump, after a blockage has been
freed or during cleaning. The diameter of this zone is twice the end
hose length.
The end hose must be allowed to hang freely.
Ensure that noone is standing in the danger zone. Keep the danger
zone under constant observation.
You must stop working immediately and press the EMERGENCY
STOP button if anyone enters the danger zone.

End hose striking out

2 12500500

1 With an end hose length of e.g. 4m

2 Danger zone = 2x end hose length = 8m

5104 BP07_320_1111EN
 Operation

Incorrect use
oftheendhose

12501901

Danger
Never bend the end hose over. Never attempt to straighten a bent
end hose by increasing the pressure. The end hose must not be in
serted in the concrete. Extension of the placing boom and end hose
beyond the length specified on the boom rating plate is forbidden.
The end hose must be secured against falling.

BP07_320_1111EN 5105
 Operation

Sucking in air

10800114

Agitator hopper Escaping compressed air

Danger
Entrapped air in the delivery line is dangerous as the compressed air
is released suddenly at the end of the delivery line and the concrete
can be blown out explosively. No air must be sucked in for this rea
son.
You should therefore always fill the agitator hopper with concrete up
to the mixer shaft during pumping operations.

5106 BP07_320_1111EN
 Operation

5.12.2 Notes on correct To supplement the notes given here, you will find comprehensive
pumping information on the following subjects in our Concrete technology"
brochure (BP2158):
− Concrete components
− Properties of freshly−mixed concrete
− Properties and conditions of freshly−mixed concrete
whenpumping
− Guide to avoid faults
− Specifications and regulations of the Technical Regulations"

You may request this brochure from Putzmeister’s After Sales

Department should you not already have a copy.

Bouncing boom

Note
If the boom bounces very heavily in pumping operations, check the
support and correct it as required. If the support is correct, reduce
the pump speed or change the boom position.

The boom can also bounce if air is taken in and compressed in the
delivery line. You should therefore make sure that the agitator hopper
is always filled with concrete to the mixer shaft and that no air is
sucked in.

BP07_321_0705EN 5107
 Operation

Favourable boom
position

32202300

Last arm horizontal

Note
A horizontal position of the last arm is favourable for pumping.

If the last arm is lower than the horizontal, the concrete in this part of
the delivery line will flow more quickly as a result of its self−weight.
The flow velocity is lower if the arm position is horizontal, and thus
the wear on the delivery pipes and the end hose is less.

When the pump is stopped, only the content of the end hose flows
out if the arm position is horizontal; the content of the delivery line
can flow out if the arm position is below the horizontal.

The strokes of the pump cause forces to act along the delivery line
and thus along the boom. If the last arm is vertical, the forces also
act vertically on the boom end and move the boom up and down.
Ifthe arm position is horizontal, the boom is moved forwards and
backwards, which causes a light rocking motion.

5108 BP07_321_0705EN
 Operation

Damping valve The damping valve is used to control the switching speed of the
transfer tube.

20203903

Hare: damping valve switch position open

Snail: damping valve switch position closed

Note
You must close the damping valve when you are pumping soft
consistence concrete (snail symbol) as otherwise the transfer tube
switches over too harshly.

You must open the damping valve (hare symbol) when you are
pumping stiff consistence concrete as the concrete has a damping
effect.

BP07_322_9704EN 5109
 Operation

5.12.3 Starting pumping The process from the start of concrete pumping to the time at which
a continuously flowing concrete stream exits from the end hose is
known as starting to pump.

The entire delivery line must be wetted at the start of pumping

operations.

11000501

Starting pumping with thin concrete

" Insert two sponge balls into the delivery line through the
wash−out port.

" Pour approximately 0.5 m3 thin concrete into the hopper.

" Switch the agitator on.

" Slowly pump the concrete into the delivery line.

The process of starting to pump with thin concrete is completed

when the two sponge balls and a solid concrete stream exit from the
end hose.

Note
You must begin pumping with a cement−water mixture (grout) if the
delivery lines are new, or if the delivery line has not been used for a
long time.

5110 BP07_323_9704EN
 Operation

5.12.4 Pumping Correct mixing of the concrete influences pumping performance.

" Mix the concrete vigorously in the truck mixer at maximum

speed. Ensure that the concrete mix is uniformly prepared.

" Add concrete additives (deflocculants, set retarding

admixtures) and mix for at least a further four minutes.

" Pour the concrete from the truck mixer, silo, etc into the agitator
hopper.

" Switch the agitator on.

" Begin delivery.

Note
Start with a low output and increase this continuously after several
cubic metres.

BP07_323_9704EN 5111
 Operation

Breaks in pumping You should avoid breaks in pumping as far as possible, as the
concrete in the delivery line can start to set, or can become
segregated due the vibrations of the machine. Note the following
points if breaks are unavoidable:
− Never leave the delivery line under pressure;
− Relieve the delivery line during short breaks in delivery by reverse
pumping briefly (2−3 strokes). Move the concrete at short intervals
by forward and reverse pumping;
− You should avoid breaks when pumping concrete with a low water
retentivity (tendency to bleeding) as the vibrations can segregate
the concrete; When you restart pumping, you must leave the pump
switched to reverse pumping until the transfer tube switches
across fully on both sides. Only then can you switch over to for
wards pumping again.
− Pump the concrete back into the agitator hopper before long
breaks in pumping. You must mix the concrete again before you
recommence pumping.

Caution
Never use force to pump segregated concrete or concrete that has
become lumpy because it is beginning to set into the delivery line.
Blockages can very easily be caused in this way.

The boom can sink during lengthy breaks in pumping as a result of

the hydraulic fluid cooling. For this reason you must never leave the
boom unattended in the extended position during breaks.

5112 BP07_323_9704EN
 Operation

5.12.5 Possible faults Faults may occur even if you have observed all the notes on correct
pumping. This section lists the faults occurring most frequently, and
indicates how to rectify them.

Blockages
2
1

3
11000601

1 Wedged aggregate
2 Cement paste
3 Boundary layer

The following faults can lead to blockages:

− delivery line insufficiently wetted;
− transfer tube leaking;
− lines leaking;
− concrete leavings in the transfer tube and delivery pipes;
− unfavourable concrete composition;
− segregated concrete;
− set concrete.

Caution
In the event of blockages, pump the concrete immediately back into
the agitator hopper and mix it up. You can switch over to forwards
pumping when the delivery cylinders and the transfer tube are
switching over automatically again without problem. Begin pumping
again with care.

BP07_324_9704EN 5113
 Operation

Overheating Continuous operation under high loading can lead to overheating of

the hydraulic fluid. All pumps have a thermo−electrical cut−out. The
pump is automatically shut down if the fluid heats up to over 90_C.
Proceed as follows to prevent this:

" Check that the hydraulic fluid radiator is operating correctly. If

not, you can switch it on using the toggle switch on the control
cabinet.

" Reduce the output.

" Fill the water box with fresh water as soon as the fluid
temperature rises above 80_ C.

Cooling

10600200

" Change the water continuously if the temperature continues to

rise.

" Look for the cause of fluid overheating and rectify it.

5114 BP07_324_9704EN
 Operation

Additional cooling

10600400

" If you absolutely must supply additional cooling, direct the

water jet onto the drive cylinders and the piston rods of the
drive cylinders.

Caution
Never spray water on the hydraulic fluid reservoir. Damage may be
caused to the hydraulic pump.

Never use sea water or water containing salt for cooling. Otherwise
the chrome layer on the delivery piston rods and delivery cylinders
will be destroyed.

BP07_324_9704EN 5115
 Operation

Restarting after Should the pump have, nevertheless, been switched off because of
overheating overheating, you should proceed as follows:

" Switch the pump off.

" Never switch the engine off, as the hydraulic fluid radiator must
remain in operation.

" Refresh the water in the water box.

" Wait until the hydraulic fluid has cooled if you are not able to
find the fault immediately.

" Once the red indicator lamp has extinguished, switch the
pump back on and continue pumping slowly at reduced
output.

" Determine the cause of the fluid overheating once pumping

operations have been completed and rectify the fault.

5116 BP07_324_9704EN
 Operation

5.12.6 Special cases On some construction sites, the reach of the placing boom may not
be sufficient. If this is the case, you have the option of connecting a
continuation delivery line to the boom tip or of connecting a delivery
line using the lateral outlet, if the machine is equipped with this.

Continuation
delivery line

22202100

Connecting the continuation delivery line

Caution
No forces must be transferred from the stationary delivery line to the
placing boom or vice versa.

The stationary delivery line must not exert an additional load on the
boom. This will impair the stability of the machine.

The delivery hose must not be kinked, and not pulled taut either. If
kinks occur, blockages may occur also. If it is pulled taut, forces may
be transferred that may lead to damage to the structure, to the deliv
ery hose or to the placing boom.

Cooling of the hydraulic fluid in the boom cylinders may cause the
placing boom to be lowered during pumping operations and to the
delivery hose becoming taut. This may cause forces to be trans
ferred or the delivery hose to tear. Therefore, keep the delivery hose
under constant observation.

BP07_325_1201EN 5117
 Operation

" Using the last arm, move the boom approx. 1.52m towards
the stationary delivery line.

Danger
Risk of injury from unintentional boom movement. Switch off the
boom functions so that the arm assembly cannot move unintention
ally.

Leave the boom functions switched off during the assembly work
and during use of the continuation delivery line.

" If possible, place the last arm on a suitable supporting struc

ture.

" Using the remote control, switch the locally latched toggle
switch (boom functions− 0− support leg control) to0".

" Remove the end placing hose.

" Attach a delivery hose (3m long) to the connection point where
the end placing hose was.

" Connect the delivery hose and the stationary delivery line
using an SKHattachment coupling. Use an Aseal.

" Secure the SKHattachment coupling firmly to the structure.

5118 BP07_325_1201EN
 Operation

5.13 Cleaning Concrete leavings that are deposited inside the delivery line or
transfer tube can cause damage, will accumulate and reduce the
cross section. It is therefore essential that delivery lines and transfer
tubes are kept clean to allow troublefree delivery the next time they
are used.

Concrete leavings deposited around the wear ring can impair its
function. For this reason, thorough flushing of the wear ring is re
quired at the end of a job, unless the next pumping job follows within
3060minutes.

Cleaning instructions

Caution
To ensure that you do not damage the paint and other surfaces of
your machine, you must observe the following:
 Never use sea water or other water containing salt for cleaning
purposes. You must rinse off any sea water that is deposited on
the machine.
 Do not use any aggressive cleaning agents.
 The water used for washing must not be hotter than 50°C
(122°F).
 The spray nozzle must be held at least 4050cm from the paint
surface.

You must also observe the following during the first 8working weeks:
 During this time, you must not use any steam jet equipment since
the paint is not fully cured.
 Furthermore, you may only use cold water for cleaning during this
period.

Lock the remote control units away in the driver’s cab during clean
ing operations. The remote control units do not have a watertight
casing. Perform the machine functions required during cleaning
operations from the control cabinet.

BP07_311_1111EN 5119
 Operation

Leavings You should always find an appropriate use for the leavings to help in
environmental protection.

Environmental protection
The leavings should be used on the construction site. The leavings
should be used as building rubble or be recycled if this is not poss
ible.

We recommend that you use the Putzmeister Leavings sheet" to

allow you to make use of the concrete leavings. You can lay this
down under the hopper before opening the hopper flap. The con
crete then flows out into the sheet and can be transported to the site
of concrete placement using a site crane.

A further option is to raise the machine on the rear support legs

enough to allow you to push a wheelbarrow under the hopper open
ing and to catch the concrete in the barrow.

If the concrete is not to be used, you should bend a length of rein

forcing steel into a hook and insert it in the concrete. Once the con
crete has set, you can transport the lump of concrete away using a
site crane.

Caution
You must fold the arm assembly as described in the Driving posi
tion" section if you decide to raise the rear of the machine to push a
wheelbarrow beneath the hopper opening.

5120 BP07_311_1111EN
 Operation

Danger
Leave the agitator grille closed during all cleaning operations, since
you could be caught by the agitator.

The automatic agitator cutout must operate correctly if it is neverthe

less necessary to open the grille.

Due to technical reasons, the hopper flap at the bottom of the

hopper cannot be secured. There is a risk of injury by crushing or
loss of limb by shearing if you reach inside. It is prohibited to reach
into the hopper from below through the hopper flap or through the
hinged elbow when it is open.

BP07_311_1111EN 1

Do not reach into the hopper.

Compressed air cleaning

Danger
There is an increased risk of accident when cleaning with com
pressed air. The cleaning operation must only be carried out by a
subject expert or under expert supervision. Putzmeister accepts no
liability for damage caused by cleaning with compressed air, if per
formed incorrectly. All persons participating in the cleaning pro
cedure must be instructed in the safety regulations.

BP07_311_1111EN 5121
 Operation

Preparations for We recommend that you carry out the preparations described below
cleaning in good time to allow you to clean the delivery line and the concrete
pump directly the site use is completed.

Sponge balls and other

accessories

2
4

1 Sponge pig
2 Sponge cube
3 Sponge ball
4 Wash−out pig

You will need sufficient numbers of sponge balls and other cleaning
accessories to clean the machine properly.

5122 BP07_317_9704EN
 Operation

Catch basket You must use the catch basket if you wish to force the concrete out
of the end of the pipe using water pressure or compressed air. It
must be designed such that the concrete can flow out unhindered,
but that the sponge ball (cube, pig) is trapped and that this simulta
neously seals off the delivery line.

Danger
A catch basket on the end of the delivery line is an absolute require
ment if you are forcing the concrete out using compressed air, as
otherwise there is a risk of injury from the wash−out sponge and
concrete as they are expelled.

The use of the catch basket is recommended when water is used to

force out the concrete, to ensure that the delivery line is sealed off,
and no water can escape.

4
31201501

1 Coupling
2 Catch basket (closed pipe section)
3 Spring pin (on both sides)
4 Catch bracket

BP07_317_9704EN 5123
 Operation

Wash−out adaptor The wash−out adaptor is used when the machine is cleaned using
water under pressure or compressed air.

Danger
A catch basket on the end of the delivery line is an absolute require
ment if you are forcing the concrete out using compressed air, as
otherwise there is a risk of injury from the wash−out sponge and
concrete as they are expelled.

5 4 3

1 Pressure gauge
2 Guard bracket
3 Connection for water or compressed air
4 Isolating valve for connection
5 Pressure dump bend
6 Pressure dump cock

5124 BP07_317_9704EN
 Operation

Cement bags for high− Cement bags soaked in water and rolled up have proved useful
pressure water cleaning when cleaning the delivery line using water under pressure. The
cement bags prevent the washing water penetrating the concrete,
flushing the concrete out and causing blockages.

Rolled−up cement bags

" Roll up 1 − 2 empty cement bags together.

" Immerse the rolled−up cement bags in water for about

5minutes before starting the cleaning operation.

Note
You may also prepare a short pipe section containing the cement
bags and a wash−out sponge before you start the cleaning oper
ation.

BP07_317_9704EN 5125
 Operation

Mark the water hose The best way to clean the wear ring and seal ring on the transfer
tube is to rinse this area with water for some time from close up. You
must mark the water hose as described below to ensure that the
hose does not get cut by the switching transfer tube during cleaning.

Danger
The machine must be switched off and the hydraulic system, includ
ing the accumulator, fully depressurized when you are measuring the
hose length required, as otherwise there is a risk of injury as the
transfer tube switches over.

20700301

1 Adhesive tape marking

" Measure the hose length required on the outside of the transfer
tube. The nozzle on the hose should be located shortly before
the seal ring so that concrete leavings are washed away from
the area around the wear ring and seal ring when the nozzle is
set to spray.

" Mark the measured length on the hose with adhesive tape, or
similar.

5126 BP07_317_9704EN
 Operation

5.13.1 Delivery line There are a number of options for cleaning a delivery line. Some of
the factors affecting which cleaning method you use include how the
concrete pump has been used and what equipment you have avail
able.

How to clean which Overleaf you will find a summary showing which cleaning method is
delivery line recommended for the delivery lines listed. The symbols used in the
summary are explained below. The cleaning procedures are de
scribed in the following sections.

Explanation of the
The delivery line is connected to the concrete pump.
symbols
The leavings are pumped by the concrete pump out of
the hopper and onwards to the site of concrete place
ment. Cleaning is from the hopper onwards to the site
of concrete placement.

The delivery line is connected to the concrete pump.

The leavings are sucked back by the concrete pump
from the site of concrete placement into the hopper.
Cleaning is backwards from the site of concrete place
ment to the hopper.

The delivery line has been disconnected from the

concrete pump. The leavings are forced forwards from
the start of the delivery line to the site of concrete
placement using an external force (compressed air or
water under pressure). Cleaning is from the start of the
delivery line to the site of concrete placement.

The delivery line has been disconnected from the

concrete pump. The leavings are forced backwards
from the the site of concrete placement to the start of
the delivery line to using an external force (com
pressed air or water under pressure). Cleaning is from
backwards from the site of concrete placement to the
start of the delivery line.

Recommended method of cleaning

Method of cleaning not recommended

Prohibited method of cleaning

Method of cleaning not possible

BP07_305_9701EN 5127
 Operation

Summary of the methods of cleaning

Leavings
from

Delivery line to

Method of
cleaning

Compressed air only with

no onwards
special
delivery line
yline

Water under pressure equipment

mp

connected to
tepum
elivery

the
h boom
b tip
i
Suction cleaning
oncrete
omdel

Compressed air only with

with onwards
Boom

special
edco

delivery line Water under pressure equipment

connected to
mounte

the boom tip

Suction cleaning
uck−m

Compressed air
Truc

Lateral outlet Water under pressure

Suction cleaning

Compressed air only with

special
deliverryline
e

Riser Water under pressure equipment

Suction cleaning
naryd

Compressed air only with

Stationa

special
Downpipe Water under pressure equipment
St

Suction cleaning

5128 BP07_305_9701EN
 Operation

Suction cleaning Suction cleaning is the simplest and least hazardous method of
cleaning. It is described below.

" Pump the agitator hopper out until the concrete is at the level
of the top of the delivery cylinder tubes.

" Then switch the pump off.

Insert the wash−out

sponge

20006201

Inserting a water−soaked wash−out sponge

" Insert a water−soaked wash−out sponge (cube) into the end

hose outlet.

BP07_306_9702EN 5129
 Operation

Shift the boom to a

rising position

20006202

Suck the concrete from the top down the line

" Shift the placing boom into a uniformly rising position.

å This makes it easier to pump the concrete back as the
concrete flows back under its own weight.

5130 BP07_306_9702EN
 Operation

Reverse pumping the

concrete

1. 2.

30500603

1 Reverse pumping
2 Pump on

" Switch the pump to reverse pumping.

å The concrete and the wash−out sponge are pumped back
through the delivery line.

BP07_306_9702EN 5131
 Operation

Check for the wash−out

sponge

20006203

Tapping on the delivery line with a hammer handle

" Tap on the delivery line with a piece of hardwood (hammer

handle) just ahead of the cleaning eye during the washing out
process.

Note
Tapping produces deep dull noises there is concrete in the delivery
line. Tapping will yield high, clear sounds as soon as the concrete
and wash−out sponge have passed the point at which you are tap
ping.

Use only a hammer handle to tap on the delivery line, as otherwise

the pipe may be damaged.

" Switch the pump off as soon as the wash−out sponge has
passed the point at which you are tapping.

5132 BP07_306_9702EN
 Operation

Trapping the wash−out

sponge

20006204

Turn the wash−out port lid round

" Open the wash−out port on the transfer tube, turn the wash−out
port lid round and close it again with the pin pointing inwards.

" Switch the pump back over to reverse pumping.

å The wash−out sponge will be trapped on the pin of the
wash−out port lid.

" Then switch the pump off.

" Open the wash−out port lid and remove the wash−out sponge.

" Repeat the washing out procedure, as a single reverse

pumping pass of a wash−out sponge is not sufficient.

BP07_306_9702EN 5133
 Operation

5.13.2 Hopper, delivery One possible method of cleaning the hopper, the delivery cylinder
cylinder and and the S transfer tube is described below.
S transfer tube
Note
This machine is equipped with an agitator safety cutout. As soon as
you open the grille, the agitator is halted and the pressure is dumped
from the accumulator. This means that the transfer tube will no longer
be able to switch over. In addition, the delivery pistons return to the
end position and the concrete pump halts. You must switch the con
crete pump off and back on again to re−start it.

Danger
In no event should you insert the water hose, the spray gun or other
objects through the grille into the hopper to spray out the delivery
cylinders. Such objects may be trapped by the transfer tube as it
switches over and become damaged. The objects may be caused to
fly about, thereby causing an injury to you or other persons.

5134 BP07_369_9711EN
 Operation

Drain off the leavings

40700201

Lay the sheet down

" Place the Putzmeister leavings sheet beneath the hopper.

" Open the hopper flap beneath the hopper and let the leavings
flow out of the hopper.

" Switch the pump over to reverse pumping.

å This pumps the leavings out of the delivery cylinders into
the hopper and thus out of the hopper opening.

BP07_369_9711EN 5135
 Operation

30000500

Hoisting the concrete away

Caution
You may only hoist a maximum of 0.5m 3 concrete (approxi
mately1200kg) using the Putzmeister leavings sheet.

" Hoist away the concrete in the Putzmeister leavings sheet.

5136 BP07_369_9711EN
 Operation

Spray out delivery

cylinder

40700202

Spray out the transfer tube and delivery cylinder with the
concrete pump running slowly in reverse

" Open the hinged elbow.

" Allow the concrete pump to run slowly in reverse.

" Spray the transfer tube out carefully downwards from the
hinged elbow. Slowly insert the hose up to the marking as you
do this (see the Mark water hose" chapter).

BP07_369_9711EN 5137
 Operation

20700304

Insert the water hose into the transfer tube as far as the marking

" Hold the water hose in this position, introduced as far as the
marking, for several minutes, until only clean water runs out.
å This will flush out the two delivery cylinders alternately.

" Carefully spray out the hopper using a hose.

" Hose down all components that have come into contact with
concrete.

5138 BP07_369_9711EN
 Operation

Cleaning the gap After each pumping operation, you must clean the transfer tube
between the transfer bearing thoroughly to prevent any concrete encrustation in the
tube bearing and the transfer tube bearing.
S transfer tube

1 2 3

1 2 4

BP07_807_1006EN 1

No. 0 Designation
1 S transfer tube
2 Transfer tube bearing
3 Square section seal ring
4 Areas that must be cleaned
5 Lubrication points
6 Hinged elbow

BP07_807_1006EN 5139
 Operation

" Open the hinged elbow(6).

" Remove the square section seal ring(3).

" Carefully spray out the areas that are to be cleaned(4) on the
transfer tube bearing(2).

" Immediately after cleaning, use the lubrication point pro

vided(5) to grease the transfer tube bearing(2).
å Grease is visible between the S transfer tube(1) and
transfer tube bearing(2).

" Clean the square section seal ring(3).

" Grease the square section seal ring(3).

" Insert the square section seal ring(3).

" Close the hinged elbow(6).

5140 BP07_807_1006EN
 Operation

Close hinged elbow The hinged elbow must be closed as follows:

2 2 3

5 4

BP07_808_1101EN 1

No. 0 Designation
1 Inscription "0" or recess
2 Retaining bolt for hinged elbow
3 Hinged elbow
4 Wedge
5 Tie bolt for retaining bolt(2)
6 Spring pin

BP07_808_1101EN 5141
 Operation

Note
The retaining bolt(2) must be screwed to the tie bolt(5) as shown in
the above illustration (inscription "0" or recess (1) facing upwards).
Only then can the wedge(4) for closing the hinged elbow be fitted.

" Check that the retaining bolt(2) is seated securely.

" Check the mounting position of the retaining bolt(2).

" Close the hinged elbow (3) with the wedge (4).

" Secure the wedge (4) using the spring pin (6).

5142 BP07_808_1101EN
 Operation

5.13.3 Truck superstructure Once the delivery line, hopper, delivery cylinders and S transfer
and post-washing tubehave been washed out, you must thoroughly rinse down all
operations other parts of the machine that have come into contact with con
crete. Concrete that is not washed off immediately can attack the
paint, especially if aggressive concrete additives have been used.

Caution
The delivery line, water box, water tank and water pump must be
drained fully if there is a risk of freezing. The water box must also be
drained at normal temperatures during longer breaks in pumping,
e.g. overnight and at weekends, etc. Leave the water outlet open
afterwards.

Danger of explosion
Atomized preserving agents are highly explosive. Keep away from all
sources of ignition whilst spraying.

Danger of poisoning
Cleaning agents, solvents or preserving agents sprayed in air can
enter the lungs and trigger serious damage to health. You should,
therefore, always wear respiratory protection during this work.

BP07_318_1006EN 5143
 Operation

" Clean all seals and the seal seats.

" Grease the seals before replacing them.

" Clean the remaining parts of the machine by rinsing down

withwater.

" At the lubrication point provided, grease all of the bearing

points in the hopper area immediately after washing it out.
å Grease is visible on the lubrication point.

" Grease all of the exposed piston rods.

" Grease the interior surfaces of the delivery cylinder.

" Lubricate the arm assembly.

" Grease the untreated surfaces of mechanical parts (race ring,

rollers, etc.).

" Then spray the metal components with an anticorrosion agent

or release agent.

Note
Please also read the High−pressure water pump" section if your
machine is equipped with a highpressure water pump.

5144 BP07_318_1006EN
 Operation

5.14 Driving position Please also read the Driving, towing and loading" chapter.

Caution
There must be no concrete in the delivery line along the arm assem
bly when the arm assembly is being folded. The arm assembly is de
signed for certain working positions while the pump is in operation;
these are described in the Operating Instructions. However, when
the arm assembly is being folded, the arm is moved to positions
which would place too heavy a load on the arm assembly if the deliv
ery line were to be full.

Always observe the specified sequence for folding and unfolding the
boom. Failure to comply with the sequence may allow the crank lever
in the Dhinge to compress the delivery line, adjacent hydraulic cylin
ders or other components.
The boom support cradle may be damaged if you do not stop the
downward movement of the boom as soon as the arm assembly is
resting on the boom support cradle.
In order to avoid damaging the boom support cradle, guide the arm
assembly in with care. Stop the boom downward movement as soon
as the arm assembly is resting on the boom support cradle.

You should further note that the end hose (depending on the ma
chine’s equipment) is positioned loosely in the end hose brackets
and hangs down freely when the boom is being folded in and out.

BP07_859_1212EN 5145
 Operation

5.14.1 Folding sequence

Caution
You must have folded arm4 in fully before you fold arm5 in fully,
otherwise the Dhinge crank lever will press against the elbow at the
boom tip.

Therefore, only fold arm5 in fully once you have folded arm4 in fully.

Arm 5

BP07_859_1212EN 1

Folding arm5

" Fold arm5 in so that the boom tip is approximately 1m from
the Dhinge.

Arm 4

BP07_859_1212EN 2

Folding arm4 in fully

" Fold arm4 in fully until it rests against arm3.

5146 BP07_859_1212EN
 Operation

Arm 5

BP07_859_1212EN 3

Folding arm5 in fully

" Now fold arm5 in fully until it rests against arm4.

Arm 3

BP07_859_1212EN 4

Folding arm3 in fully

" Fold arm3 in fully until it rests against arm2.

BP07_859_1212EN 5147
 Operation

Arm 2

BP07_859_1212EN 5

Folding in arm2 and catching the end hose

" Then fold in arm2.

å The end hose will automatically drop into the catch
brackets.

Lowering the arm

assembly onto the
cradle

2.

1.

BP07_859_1212EN 6

Slewing and lowering the arm assembly

" Slew the arm assembly until it is in the storage position and
then lower it.

Note
The arms must be fully retracted and lie on the boom cradle pro
vided.
Check that the end hose is secured in the transport security device.

5148 BP07_859_1212EN
 Operation

5.14.2 Retracting The same safety and operational regulations apply for retracting the
the supports supports as for extending them. See also the Supporting the ma
chine" chapter.

Interlock

2
12100101

Snaplock

" Remove the spring pins on all snaplocks.

" Unlock all snaplocks.

Note
The snaplocks lock the support legs again automatically as soon as
they have reached their end position.

BP07_062_1201EN 5149
 Operation

Danger of crushing
There is a risk of crushing in the swingout and extension zone for
the supports.
You should therefore secure the danger zone. Keep the danger zone
under constant observation.
You must cease working immediately and press the EMERG
ENCYSTOP button if unauthorized persons enter the danger zone.

5.14.3 Remote control

2

10504701

Preselection switch

" Switch the toggle switch on the remote control to Supports

On".

5150 BP07_062_1201EN
 Operation

Caution
The truck must also only reach a maximum tilt position of 3_ when
the support feet are being retracted.

" Retract the rear support feet first, then the forward support feet.

" Now swing the support legs in or retract them.

" Switch the toggle switch on the remote control to the Supports
Off" position.

" Secure all the snaplocks with spring pins.

" Remove the remote control and lock it away in the driver’s cab.

" Disengage the power take−off.

" Secure the end hose and the accessories against falling from
the truck.

BP07_062_1201EN 5151
 Operation

5.14.4 Disengaging the The machine is not ready to drive until the transfer gearbox has been
transfer gearbox disengaged and driving mode selected.
power take–off
The following information describes how a manual gearbox is
operated. In the case of an automatic gearbox, also check the
dataprovided by the vehicle manufacturer.

Caution
When engaging and disengaging the transfer gearbox, the vehicle
gearbox must be in the neutral position. The Cardan shaft must not
turn.

3a

1 2 3

3b

BP07_594_0809EN 1

No. 0 Designation
1 Green indicator lamp
2 Red warning lamp
3 Locally latched toggle switch
3a Pumping operations" switch position
3b Driving" switch position

Note
To use a locally latched toggle switch, you must first pull it out and
then push it towards the symbol.

5152 BP07_594_0809EN
 Operation

" Operate the clutch pedal.

" Shift the vehicle gearbox to the neutral position.

" Switch the locally latched toggle switchin the driver’s cab from
pumping operations to driving.
å The green indicator lamp in the dashboard goes out and
the machine is then ready to drive.

Note
If the green indicator lamp is still lit and the red warning lamp lights
up in the dashboard, the parking brake is not applied.
You must then apply the parking brake and repeat the gear shift.

" Select the desired gear for driving, slowly release the clutch
pedal and release the parking brake.
å The green indicator lamp and the red warning lamp in the
dashboard go out.

Note
If the green indicator lamp and the red warning lamp in the dash
board are still lit at this point, it is because the gear shift lasts several
seconds. Normally, both lamps go out after this time and the machine
is then ready to drive.

However, if the green indicator lamp and the red warning lamp stay
lit then there is a fault with shifting. Shifting faults may arise due to
synchronisation problems in the transfer gearbox.

BP07_594_0809EN 5153
 Operation

Rectifying shifting If there is a shifting fault in the transfer gearbox, rectify the fault as
faults in the transfer follows:
gearbox
Danger
The machine is not ready to drive until the fault has been rectified.
Ifyou continue driving after engaging driving operation despite the
fault, this will lead to damage to the transfer gearbox and the truck.

" Run the engine.

" Apply the parking brake.

" Shift the vehicle gearbox to the neutral position and keep the
clutch pedal depressed.

" Switch the locally latched toggle switch from driving back to
pumping operations.

" Switch the locally latched toggle switch from pumping oper
ations back to driving.

" Select the desired gear for driving, slowly release the clutch
pedal and release the parking brake.
å The green indicator lamp and the red warning lamp in the
dashboard go out.

5154 BP07_594_0809EN
 Operation

Caution
If you hear a clattering noise from the gearbox, depress the clutch
pedal immediately and repeat the shifting procedure. Incorrect oper
ation during the shifting procedure can result in gearbox damage.

Danger
If there is still a shifting fault in the transfer gearbox, you may only
repeat the procedure 2 to 3 times without causing any damage.
If a shifting fault cannot be rectified, contact the Putzmeister after−
sales service (APS department).

BP07_594_0809EN 5155
 Operation

5.15 Driving position Also read the Driving, towing and loading" chapter and the Unfold
when using One-Side- ing the 5RZ boom" section.
Support
Caution
There must be no concrete in the delivery line along the arm assem
bly when the arm assembly is being folded. The arm assembly is de
signed for certain working positions while the pump is in operation;
these are described in the Operating Instructions. However, when
the arm assembly is being folded, the arm is moved to positions
which would place too heavy a load on the arm assembly if the deliv
ery line were to be full.

Always observe the specified sequence for folding and unfolding the
boom.
The boom support cradle may be damaged if you do not stop the
downward movement of the boom as soon as the arm assembly is
resting on the boom support cradle.
In order to avoid damaging the boom support cradle, guide the arm
assembly in with care. Stop the boom downward movement as soon
as the arm assembly is resting on the boom support cradle.

You should further note that the end hose (depending on the ma
chine’s equipment) is positioned loosely in the end hose brackets
and hangs down freely when the boom is being folded in and out.

Arm 5

BP07_860_1212EN 1

Folding arm5

" Fold arm5 in so that the boom tip is approximately 1m from
the Dhinge.

5156 BP07_860_1212EN
 Operation

Arm 4

BP07_860_1212EN 2

Folding arm4 in fully

" Fold arm4 in fully until it rests against arm3.

Arm 5

BP07_860_1212EN 3

Folding arm5 in fully

" Now fold arm5 in fully until it rests against arm4.

BP07_860_1212EN 5157
 Operation

Arm 3

BP07_860_1212EN 4

Folding arm3 in fully

" Fold arm3 in fully until it rests against arm2.

Arm 2

BP07_860_1212EN 5

Folding in arm2 and catching the end hose

" Then fold in arm2.

å The end hose will automatically drop into the catch
brackets.

5158 BP07_860_1212EN
 Operation

Arm assembly vertical

BP07_860_1212EN 6

" Raise the arm assembly to the vertical.

2.
1.

BP07_860_1212EN 7

" Then slew the arm assembly to the rest position by the shortest
route and lower it onto the support cradle.

Note
The arms must be fully retracted and lie on the boom cradle pro
vided.
Check that the end hose is secured in the transport security device.

BP07_860_1212EN 5159
 Operation

5.15.1 Retracting The same safety and operational regulations apply for retracting the
the supports supports as for extending them. See also the Supporting the ma
chine" chapter.

Interlock

2
12100101

Snaplock

" Remove the spring pins on all snaplocks.

" Unlock all snaplocks.

Note
The snaplocks lock the support legs again automatically as soon as
they have reached their end position.

5160 BP07_062_1201EN
 Operation

Danger of crushing
There is a risk of crushing in the swingout and extension zone for
the supports.
You should therefore secure the danger zone. Keep the danger zone
under constant observation.
You must cease working immediately and press the EMERG
ENCYSTOP button if unauthorized persons enter the danger zone.

5.15.2 Remote control

2

10504701

Preselection switch

" Switch the toggle switch on the remote control to Supports

On".

BP07_062_1201EN 5161
 Operation

Caution
The truck must also only reach a maximum tilt position of 3_ when
the support feet are being retracted.

" Retract the rear support feet first, then the forward support feet.

" Now swing the support legs in or retract them.

" Switch the toggle switch on the remote control to the Supports
Off" position.

" Secure all the snaplocks with spring pins.

" Remove the remote control and lock it away in the driver’s cab.

" Disengage the power take−off.

" Secure the end hose and the accessories against falling from
the truck.

5162 BP07_062_1201EN
 Operation

5.15.3 Disengaging the The machine is not ready to drive until the transfer gearbox has been
transfer gearbox disengaged and driving mode selected.
power take–off
The following information describes how a manual gearbox is
operated. In the case of an automatic gearbox, also check the
dataprovided by the vehicle manufacturer.

Caution
When engaging and disengaging the transfer gearbox, the vehicle
gearbox must be in the neutral position. The Cardan shaft must not
turn.

3a

1 2 3

3b

BP07_594_0809EN 1

No. 0 Designation
1 Green indicator lamp
2 Red warning lamp
3 Locally latched toggle switch
3a Pumping operations" switch position
3b Driving" switch position

Note
To use a locally latched toggle switch, you must first pull it out and
then push it towards the symbol.

BP07_594_0809EN 5163
 Operation

" Operate the clutch pedal.

" Shift the vehicle gearbox to the neutral position.

" Switch the locally latched toggle switchin the driver’s cab from
pumping operations to driving.
å The green indicator lamp in the dashboard goes out and
the machine is then ready to drive.

Note
If the green indicator lamp is still lit and the red warning lamp lights
up in the dashboard, the parking brake is not applied.
You must then apply the parking brake and repeat the gear shift.

" Select the desired gear for driving, slowly release the clutch
pedal and release the parking brake.
å The green indicator lamp and the red warning lamp in the
dashboard go out.

Note
If the green indicator lamp and the red warning lamp in the dash
board are still lit at this point, it is because the gear shift lasts several
seconds. Normally, both lamps go out after this time and the machine
is then ready to drive.

However, if the green indicator lamp and the red warning lamp stay
lit then there is a fault with shifting. Shifting faults may arise due to
synchronisation problems in the transfer gearbox.

5164 BP07_594_0809EN
 Operation

Rectifying shifting If there is a shifting fault in the transfer gearbox, rectify the fault as
faults in the transfer follows:
gearbox
Danger
The machine is not ready to drive until the fault has been rectified.
Ifyou continue driving after engaging driving operation despite the
fault, this will lead to damage to the transfer gearbox and the truck.

" Run the engine.

" Apply the parking brake.

" Shift the vehicle gearbox to the neutral position and keep the
clutch pedal depressed.

" Switch the locally latched toggle switch from driving back to
pumping operations.

" Switch the locally latched toggle switch from pumping oper
ations back to driving.

" Select the desired gear for driving, slowly release the clutch
pedal and release the parking brake.
å The green indicator lamp and the red warning lamp in the
dashboard go out.

BP07_594_0809EN 5165
 Operation

Caution
If you hear a clattering noise from the gearbox, depress the clutch
pedal immediately and repeat the shifting procedure. Incorrect oper
ation during the shifting procedure can result in gearbox damage.

Danger
If there is still a shifting fault in the transfer gearbox, you may only
repeat the procedure 2 to 3 times without causing any damage.
If a shifting fault cannot be rectified, contact the Putzmeister after−
sales service (APS department).

5166 BP07_594_0809EN
 Operation

5.16 Measures for If you are placing concrete pumps or placing booms into storage
preserving the value formore than four weeks, you must carry out the following measures
of concrete pumps in order to preserve their value. Carry out these measures at least
and placing booms every 3months. If required due to the climatic conditions to which
in storage the stored machine is exposed, you must carry out these measures
at shorter intervals.

Checklist for value preservation measures for concrete pumps and placing booms
in storage

Assembly Action
Document the date that the machine is placed into storage and
Documentation
the value preservation measures that are carried out.
Protect the untreated surfaces (control blocks, pins, spring pins,
etc.) with a suitable preserving agent.
General Grease the untreated surfaces of mechanical parts (rollers,
chains, etc.) with Vaseline.
Rectify any corrosion damage.
Disconnect the battery.
For DEUTZ motors with an EMR3electronic engine governor,
seethe procedure for switching off on page5169.
Electrical system Check the battery charge state and charge the battery
ifnecessary.
Connect the central control unit (CCU) to a supply voltage at
sixmonthly intervals.
Empty the water tank and the water lines. Leave the drainage
openings open.
Water Drain the water box. Leave the drainage openings open.
Closethe water box cover.
Drain the highpressure water pump.
Check that the coolant contains sufficient antifreeze and
corrosion inhibitor.
Engine
Cover any exhaust pipes that exit upwards.
Detach exhaust pipes from the turbocharger.

BP07_797_1006EN 5167
 Operation

Assembly Action
Lubricate the arm assembly.
Boom Detach the end hose.
Grease all exposed piston rods with Vaseline.
Check the function of hose reels on machines larger than an M52:
Support
Fully extend the front support legs 10times.
Grease all exposed piston rods with Vaseline.
Concrete pump
Grease the interior surfaces of the delivery cylinder with Vaseline.
Grease the untreated surfaces of mechanical parts (race ring,
Truck mixer drum rollers, etc.) with Vaseline.
Close the full lock on the intake hopper.
Open and lock the hopper flap.
Hopper
pp Close the spray guard.
Spray the hopper area with barrier agent.
Vehicle superstructure Grease all exposed piston rods with Vaseline.

5168 BP07_797_1006EN
 Operation

Caution
The instructions in this warning notice apply to DEUTZ motors with
an electronic engine governor (EMR3).

You may only disconnect or switch off the battery once the control
unit has completed its rundown time (approximately 20seconds).
Interrupting this rundown time will cause a fault in the control unit.
This fault is shown continuously in the display, which means that
yourun the risk of overlooking other faults.
When you switch off the engine, you must follow the instructions
below:
 Only switch off the engine using the ignitionstarter switch.
 Do not unplug the control unit connector when the power supply
isswitched on (ignitionon).
 If maintenance work is to be carried out on the machine (e.g.
electrical welding work), you must always disconnect all plugin
connections from the control unit.

Putzmeister will not accept warranty claims for engine damage and
operating errors that result from a failure to switch off the engine
according to the instructions.

BP07_797_1006EN 5169
 6 Index of key words

In this section you will find the most important key words with the
number of the page on which you will find the key word as a heading
in the left margin. This Index of key words is listed alphabetically by
the main concepts. These are subdivided into associated sub−con
cepts, marked with a dash.

BP11_001_0201EN

A  Spontaneous retraction of the boom
Abbreviations, G  15
Accessories and attachments, 2  14
Accumulator, 3  127
Accumulator dump valve, 3  127
Additional lubrication procedure,
5  26
Aerials, Radio, telephone, etc., 3  74
After Sales Service personnel, Defini-
tion of terms, 2  3
Agitator, Control panel, 3  66
Agitator hopper, Pumping operations,
5  106
Agitator safety cutout, 3  120
 Acknowledge, 5  22
 Inspection, 5  67
 Unexpected restart, 5  22
Arm assembly, Definition of terms,
2  1
Authorized inspector, Definition of
terms, 2  3
Auxiliary personnel, Definition of
terms, 2  2
B  Technical data, 3  48
Base structure, Definition of terms,
2  1
Battery, Radio remote control, 5  12,
5  13, 5  15
Blockages, 2  41, 5  113
Boom
 Bounce, 5  107
 Description of the functions, 3  13
 Favourable boom position, 5  108
 Folding, 5  145
 Folding when using OneSideSupport,
5  156
 Impermissible working range, 5  93
 Unfolding, 5  86
 Unfolding when using One−Side−Sup
port, 5  94
Boom control block, Inspection, 5  66
Boom movements, 5  69
 Danger zone, 5  71
 Hand signals, 5  74, 5  79
 High−voltage lines, 5  72
 Prohibited activities, 5  69
Indexofkeywords
 Signalling with the horn, 5  73
cylinders, 5  75
 Spontaneous retraction of the support
cylinders, 5  75
 Uncontrolled boom movements, 5  77
Boom pedestal, Definition of terms,
2  1
Boom speed
 Cable remote control, 5  21
 Programming your own boom speed,
3  93
 Radio remote control, 5  9
Bouncing boom, 5  107
Breaks in pumping, 5  112
C Connecting
Cable remote control, 3  68, 5  17
 Boom speed, 5  21
 Connecting, 5  17
Catch basket, 5  123
Centralized gauge ports, 3  128
Centralized lubrication system, 3  48,
5  23, 5  24
 Additional lubrication procedure, 5  26
 Filling the lubricant reservoir, 5  24
Charger, Radio remote control bat-
tery, 3  111
Check functional fluids, 5  2
Cleaning, 2  46, 5  119
 Catch basket, 5  123
 Cement bags, 5  125
 Cleaning agents, 2  47
 Compressed air, 2  48
 Compressed air cleaning, 5  121
 Delivery cylinder, 5  134
 Delivery line, 5  127
 Hazards, 2  47
 High−pressure water cleaning, 5  125
 Hopper, 5  134
 Leavings, 5  120, 5  135
 Mark the water hose, 5  126
 Methods of cleaning for delivery lines,
5  128
 Notes, 5  119
 Post−cleaning procedure, 2  49, 5  143
 Preparations for cleaning, 5  122
 S transfer tube, 5  134
 Sponge ball, 5  122
 Suction cleaning, 5  129
 Vehicle superstructure, 5  143
 Wash−out adaptor, 5  124
Cleaning agents, 2  47
Clearances
 From high−voltage lines, 2  21
 Minimum clearance from pits, 5  31
 Safe clearance from pits, 5  32
 To delivery lines, 2  42
Cold weather, 2  39, 5  71
Components, Overview, 3  1
Compressed air cleaning, 2  48, 5  121
Concrete brake, 3  131
Concrete pump, Definition of terms,
2  1
 Cable remote control, 5  17
 Radio remote control, 5  9
Control block
 Boom, 3  126
 Support, 3  123
Control cabinet
 Central modular control cabinet, 3  19
 Ergonic Graphic Display, 3  22
 OSS door module, 3  21
Control devices
 Accumulator dump valve, 3  127
 Boom control block, 3  126
 Cable remote control, 3  68
 Central modular control cabinet, 3  19
 Control panel in the steps, 3  66
 Hydraulic fluid radiator, 3  140
 Magnetic switches distributor casing,
3  116
 OSS door module, 3  21
 Pump control system, 3  127
 Radio remote control, 3  70
 Support control block, 3  123
 Vibrator, 3  139
Control panel
 Agitator, 3  66
 Flushing water pump, 3  66
 Highpressure water pump, 3  66
 In the steps, 3  66
 With centralized lubrication system,
3  48
Copyright, 1  2
Corner bearing load, 2  29, 5  35
i
 Indexofkeywords
D Designated use, 2  9
Danger zone, 2  4, 2  7
 Boom movements, 5  71
 Delivery line systems, 2  8
 Guiding the end hose, 2  8, 2  37
 Hopper, 2  8
 Machine, 2  8
 Placing boom, 2  7
 Pumping operations, 5  103
 Set−up site, 5  30
 Support legs and support feet, 2  7
 Supports, 5  45
Definition of terms
 After Sales Service personnel, 2  3
 Arm assembly, 2  1
 Authorized inspector, 2  3
 Auxiliary personnel, 2  2
 Base structure, 2  1
 Boom pedestal, 2  1
 Concrete pump, 2  1
 Danger zone, 2  4, 2  7
 Delivery line systems, 2  2
 Guiding the end hose, 2  2
 Hoseman, 2  2
 Machine, 2  1
 Machine operator, 2  2
 Maintenance, 2  3
 Manufacturer, 2  2
 Operator, 2  2
 Place of work, 2  4, 2  6
 Placing boom, 2  1
 Qualified personnel, 2  3
 Signaller, 2  2
 Subject expert, 2  3
 Truck mixer, 2  2
 Truck mixer driver, 2  3
 Working area, 2  4, 2  6
Delivery cylinder, Cleaning, 5  134
Delivery line
 Cleaning, 5  127
 Description of the functions, 3  13
Delivery line systems, 2  40
 Clearance to delivery lines, 2  42
 Continuation delivery lines, 2  43
 Danger zone, 2  8
 Definition of terms, 2  2
 Fastening delivery lines, 2  42
 Opening the delivery line, 2  42
 Securing delivery lines, 2  40
 Shutting−off, diverting, cleaning, 2  43
 Suitable delivery line, 2  40
ii
 Tightness and blockages, 2  41
 Inspection intervals, 2  10
 Retesting, 2  9
Discharge voltage pattern, 2  21
Driving, 2  32, 4  1
 Before moving off, 4  2
 During the journey, 4  3
 Hand signals, 4  1, 4  4
 Rectifying shifting faults in the transfer
gearbox, 5  6, 5  154, 5  165
Driving position
 Disengaging the transfer gearbox,
5  152, 5  163
 Folding the boom, 5  145
 Folding the boom when using One
SideSupport, 5  156
 Retracting the supports, 5  149, 5  160
Dry running cut-out, High-pressure
water pump, 3  32
Dual-section end hose, 3  133
E  Output current monitoring, 3  103
Earthing, 2  24
EGD, see Ergonic Graphic Display,
3  22
EGD symbols
 Agitator safety cutout, 3  32
 Cause of pump stoppage, 3  37
 Centralized lubrication system, 3  33,
3  38, 3  45
 Compressor, 3  46
 EMERGENCY STOP, 3  32
 Engine speed, 3  36
 Ergonic Output Control, 3  47
 Fault, 3  32
 High pressure, 3  38
 Highpressure water pump dry running
cutout, 3  32
 Hopper filllevel sensor, 3  39
 Hydraulic fluid overheating, 3  37
 Hydraulic fluid radiator, 3  33, 3  47
 Magnetic switches, 3  36
 Output current monitoring, 3  38
 Push Over, 3  47
 Service operation, 3  46
 Squeeze valve, 3  46
 Stroke counter, 3  47
 Transfer tube, 3  36
 Vacuum return flow filter, 3  33, 3  39
 Warning, 3  32
EGD–RC, See Ergonic Graphic Dis-
play – Remote Control, 3  75
EGD–RC symbols
 Agitator, 3  84
 Agitator safety cutout, 3  86
 Boom fault, 3  104
 Boom speed preselection, 3  83, 3  92
 Centralized lubrication system fault,
3  104
 EMERGENCY STOP, 3  103
 Engine speed, 3  102
 EOC, 3  83, 3  86
 Fault, 3  103
 High pressure, 3  102
 Hopper filllevel sensor, 3  86
 Hydraulic fluid overheating, 3  103
 Hydraulic fluid radiator, 3  86
 Inhibiting slewing movement, 3  92
 Insufficient hydraulic fluid prewarning,
3  104
 Locking the boom arm, 3  92
 Lower limit, 3  87, 3  98
 Magnetic switches, 3  104
 Preferred position for arm 1, 3  88,
3  99
 Preferred position for arm 1 and arm 2,
3  88, 3  99
 Preferred position for arm 1 and last
arm, 3  88, 3  99
 Preferred position for last arm, 3  88,
3  99
 Pressure sensor, 3  105
 Programming the boom speed, 3  83,
3  92
 Pumping operation − Service opera
tion, 3  84
 Push Over, 3  84
 Slewing gear limit to the left, 3  87,
3  98
 Slewing gear limit to the left and right,
3  88, 3  99
 Slewing gear limit to the right, 3  87,
3  98
 Space angle sensor, 3  105
 Squeeze valve, 3  84, 3  86
 Store function, 3  83, 3  92
 Storing and deleting, 3  83
 Upper limit, 3  87, 3  98
 Vacuum return flow filter, 3  86
 Vibrator, 3  84
Electromagnetic compatibility, 3  6

Electrostatic charging, 2  24
EMC, 3  6
EMERGENCY STOP button, 2  36,
3  113, 5  65
EMERGENCY STOP function, 5  64
End hose, 3  130, 5  104
 **Protective sleeve with Velcro faste
ner**, 3  135
 Concrete brake, 3  131
 Danger zone, 5  103
 Dualsection end hose, 3  133
 Protective bell, 3  133
 Retaining rope, 3  132
 With flow restrictor, 3  131
EOC, Ergonic Output Control, 3  62
Ergonic Graphic Display, 3  22
 Engine diagnosis, 3  56
 Fault memory, 3  59
 HOME, 3  28
 Info, 3  61
 Menu structure, 3  25
 Operating elements, 3  23
 Pump flow meter, 3  50
 Pump settings, 3  41
 Pump status, 3  34
 Service, 3  60
 Test screen, 3  27
Ergonic Graphic Display – Remote
Control, 3  75
 Menu 1, 3  82
 Menu 2, 3  85
 Menu 3, 3  89
 Menu 4 (with EBC), 3  96
 Menu 4 (without EBC), 3  91
 Menu 6, 3  100
 Menu 7, 3  101
 Menu structure, 3  78
 Menu8, 3  106
 Operating elements, 3  75
 Radio link fault, 3  79
 Standard displays, 3  80
 Test screen, 3  79
Ergonic Output Control, 3  62
Extensions, End hose and placing
boom, 2  12
F  Pumping operations, 5  79
Face mask, 2  19
Indexofkeywords
Fill level of the delivery cylinders, Cal-
culation example, 3  55, 3  110
Filling the lubricant reservoir, 5  24
Filter, Vacuum return flow filter, 5  62
Filter functions, Vacuum return flow
filter, 5  62
Flash over, 2  23
Flow restrictor on the end hose,
3  131
Flushing water pump, 3  136
 Control panel, 3  66
Function checks, 5  60
 Agitator safety cutout, 5  67
 Boom control block inspection, 5  66
 EMERGENCY STOP function, 5  64
 Filter functions, 5  62
 Magnetic switches, 5  60
 Pump functions, 5  60
Function description, 3  13
 Boom, 3  13
 Delivery line, 3  13
 Hydraulic control, 3  13
 Pump, 3  14
 Support legs, 3  13
 Transfer tube, 3  14
G Inspection intervals, 2  10
General conditions
 For using a concrete pump, 3  15
 Height of job, 3  16
 Operating temperature, 3  17
 Service life, 3  15
 Site of use, 3  16
Guiding the end hose, 2  37
 Danger zone, 2  8, 2  37
 Definition of terms, 2  2
 Ergonomically, 2  38
 Extending, 2  12
 Impermissible end hose, 2  12
H M
Hand signals, 4  1, 5  74
 Boom movements, 5  79
 Driving, 4  4
Hearing protectors, 2  18
Height of job, 3  16
High–pressure delivery, 2  14
High–pressure water cleaning, 5  125
High–voltage lines, 2  21, 5  72
 Clearances, 2  21
 High−voltage warning device, 2  23
 Procedure in the event of a flash over,
2  23
High–voltage warning device, 2  23
High-pressure water pump
 Control panel, 3  66
 Dry running cutout, 3  32
Hopper
 Cleaning, 5  134
 Danger zone, 2  8
Hoseman, Definition of terms, 2  2
Hydraulic control, Description of the
functions, 3  13
Hydraulic fluid, Radiator, 3  140
Hydraulic fluid radiator, 3  140
I
Icons, 1  3
Immobiliser, 5  1
Impermissible end hose, 2  12
Impermissible working area, 2  6,
2  13
Interlock, 5  43, 5  149, 5  160
L
Leavings, 5  120, 5  135
Liability, Exclusion, 2  14
Lifting loads, 2  11, 2  26
Lifting points, 2  34
Loading, 2  26, 2  34, 4  10
 Lifting points, 2  34
Machine
 Danger zone, 2  8
 Definition of terms, 2  1
 Moving machine components, 2  45
 Observing, 2  45
Machine operator
 Definition of terms, 2  2
iii
 Indexofkeywords
 Responsibility of the machine operator,
2  15
Magnetic switches, 3  116
 Connector with LEDs, 3  118
 Function check, 5  60
Magnetic switches distributor casing,
3  116
Maintenance, Definition of terms, 2  3
Manufacturer, Definition of terms, 2  2
Microfilter, 3  143
Mobile machines, 2  27
 Setup site, 2  27
 Supporting ground, 2  28
Modular control cabinet, 3  19
 Additional control and operating ele
ments, 3  21
O  Protective goggles, 2  19
One–Side–Support, 5  53
 Folding the boom, 5  156
 Prohibited working range, 5  97
 Supporting the machine, 5  53
 Unfolding the boom, 5  94
Operating Instructions, 2  16
Operating procedures, 2  16, 2  17
Operating temperature, 3  17
Operator, Definition of terms, 2  2
OSS
 (One−Side−Support), 5  53
 Folding the boom, 5  156
 OSS equipment, 3  21
 Prohibited working range, 5  97
 Supporting the machine, 5  53
 Unfolding the boom, 5  94
OSS equipment, 3  21
Output, Ergonic Output Control, 3  62
Overview of the components, 3  1
P  Damping valve, 5  109
Personal protective equipment, 2  18
Personnel, 2  15
 Qualifications, 2  15
 Requirements, 2  15
 Responsibility of the machine operator,
2  15
iv
Place of work, 2  4, 2  6
 Place of work − hoseman, 2  6
Q
 Place of work − machine operator, 2  6 Qualifications, 2  15
 Place of work − truck mixer driver, 2  6
Qualified personnel, Definition of
 Pumping operations, 2  44 terms, 2  3
Placing boom, 2  35, 2  39
 Climbing, 2  13
 Danger zone, 2  7 R
 Definition of terms, 2  1
Radio remote control, 5  9
 Extending, 2  12
 Battery charger, 3  111
 Procedure in storms, 2  39
 Boom speed, 5  9
 Unfolding, 2  35
 Changing the battery, 5  12
 Wind speeds, 2  39
 Charging the battery, 5  13, 5  15
Power take–off, Transfer gearbox, 5  3  Connecting, 5  9
Protective equipment, 2  18  Ergonic Graphic Display−Remote
 Face mask and respiratory protector, Control, 3  75
2  19  Receiver, 3  72
 Hearing protectors, 2  18  Storing batteries, 5  16
 Protective gloves, 2  19  Transmitter, 3  70
Rating plate
 Safety footwear, 2  18  Boom, 3  8
 Safety harness, 2  19  Machine, 3  7
 Safety helmet, 2  18
Reaches, 3  12
Protective gloves, 2  19  Extending, 2  11
Protective goggles, 2  19 Ready for operation
Pump, Description of the functions,  Checking, 2  20
3  14  Rendering the machine ready, 2  20
Pump control system, 3  127 Regulations, 2  16, 2  17
Pump flow meter, 3  50 Remote control, 2  44, 5  8
Pump functions, 5  60  Support function, 5  42, 5  52, 5  59,
 Stroke length, 5  61 5  150, 5  161
 Stroke time, 5  61 Removing obstacles, 2  11
 Switch over, 5  60 Respiratory protection, 2  19
Pumping operation, 3  46 Responsibility of the machine opera-
tor, 2  15
Pumping operations, 2  44, 5  103
 Agitator hopper, 5  106 Restrictions
 Blockages, 5  113  Bad weather, 5  70
 Breaks in pumping, 5  112  Boom movements, 5  70
 Calm pumping, 5  107  Cold weather, 2  39, 5  71
 Cooling, 5  114  Storm, 5  70
 Cooling, additional, 5  115  Wind, 5  70
Retaining rope, 3  132
 Favourable boom position, 5  108
Retesting, 2  9
 Hand signals, 5  79
 Overheating, 5  114
 Pumping, 5  111
 Restarting, 5  116
S
 Safety, 2  44 Safety equipment, 3  3
 Starting pumping, 5  110 Safety footwear, 2  18
 Sucking in air, 5  106
Safety harness, 2  19

Safety helmet, 2  18
Service life, 3  15
Service operation, 3  46
Set–up site, 5  27
 Calculation examples for the support
area, 5  35
 Corner bearing load, 5  35
 Danger zone, 5  30
 Lightning, 5  30
 Minimum clearance from pits, 5  31
 Safe clearance from pits, 5  32
 Space requirement, 5  28
 Support area, 5  34
 Support plate, 5  34
 Supporting ground, 5  32
 Table of timber block lengths, 5  36
Set-up site, 2  25, 2  27
 High−voltage lines, 2  21
 Supports, 2  30
Signaller, Definition of terms, 2  2
Sinking of the boom, 5  77
Site of use, 3  16
Sound power level, 3  10
Sound pressure level, 3  10
Space requirement, 5  28
 Normally supported, 5  28
 One−Side−Support, 5  29
Spirit level, 3  125, 5  47
Stability, 5  46
Starting up, 5  1
 Functional fluids, 5  2
 Immobiliser, 5  1
 Test run, 5  1
 With cable remote control, 5  19, 5  20
 With radio remote control, 5  10, 5  11
Stationary booms, 2  25
Stationary machines, 2  25
 Lifting machines, 2  26
 Loading, 2  26
 Setup site, 2  25
 Stationary booms, 2  25
 Transporting, 2  26
STOP button, 3  73
Storm, 2  39
Subject expert, Definition of terms,
2  3
Support, Extending for One–Side–
Support, 5  53
Indexofkeywords
Support area, 5  34 Transfer tube damping, 3  127
 Calculation example, 5  35 Transporting, 2  26
 Table of timber block lengths, 5  36
Transporting goods, 2  11
Support legs, Description of the func-
Truck mixer, 2  45
tions, 3  13
 Definition of terms, 2  2
Support legs and support feet, Dan-
ger zone, 2  7 Truck mixer driver, 2  45
 Definition of terms, 2  3
Support plate, 5  34
Supporting ground, 2  28, 5  32
 Corner bearing loads, 2  29 U
Supports, 2  30, 5  40 Uncontrolled boom movements, 5  77
 Danger zone, 5  45
Unexpected restart, Agitator safety
 Forward support feet, 5  50
cutout, 5  22
 Forward support legs, 5  48
Use contrary to designated use, 2  11
 Interlock, 5  43
 Accessories and attachments, 2  14
 One−Side−Support, 5  53
 OSS, 5  53  Climbing the placing boom, 2  13
 Rear support feet, 5  51  Exclusion of liability, 2  14
 Rear support legs, 5  49  Extending the reach, 2  11
 Remote control, 5  42, 5  52, 5  59,  Extensions, 2  12
5  150, 5  161  High−pressure delivery, 2  14
 Impermissible end hose, 2  12
 Spirit level, 3  125, 5  47
 Stability, 5  46  Impermissible working area, 2  13
 Working area, 5  41  Lifting loads, 2  11
 Removing obstacles, 2  11
Symbols, 1  3
 Transporting goods, 2  11
Symbols for the control system, G  1
User define, See Boom speed, 3  93
T V
Technical data, 3  6
Value preservation of machines in
 Centralized lubrication system, 3  48
storage, 5  167
 Sound power level, 3  10
 Sound pressure level, 3  10 Vehicle superstructure, Cleaning,
5  143
Technical description, Flushing water
pump, 3  136 Vibrator, 3  139
Technical terms, G  15
Temperatures, 3  17 W
 Restrictions, 2  39
Wash–out adaptor, 5  124
Test run, 5  1
Water, 2  49
Timber blocks, 5  36
Water box
Towing, 2  33, 4  6  Draining, 3  137, 5  100
Transfer gearbox  Filling, 3  137, 5  100
 Disengaging, 5  152, 5  163 Water hose, Marking, 5  126
 Rectifying shifting faults in the transfer
Wind speeds, 2  39
gearbox, 5  6, 5  154, 5  165
 Switching on, 5  3 Working area, 2  4, 2  6, 5  41
 Impermissible working area, 2  5, 2  6,
Transfer tube
2  13
 Cleaning, 5  134
 Impermissible working range, boom,
 Description of the functions, 3  14
5  93
v
 Indexofkeywords

 Overlaps, 5  73
 Permitted working area, 2  5
Working with the machine
 Before starting work, 2  20
 Checking that the machine is ready for
operation, 2  20
 Rendering the machine ready for ope
ration, 2  20

vi
 7 Glossary

This chapter illustrates the control system symbols (icons for con
crete pumps) and explains the abbreviations and technical terms
that are used in Putzmeister Operating Instructions.

BP14_001_0501EN
 Glossary

G–1 Symbols for concrete pumps in accordance with German Mechanical Engineering
Association Standard (VDMA 24119)

G–1.1 General (for key, see page G — 7)

3701 3713 3725 5008 6012 7005

3702 3714 4001 6001 6013 7006

3703 3715 4002 6002 6014 7007

3704 3716 4003 6003 6015 7008

3705 3717 4004 6004 6016 7009

3706 3718 5001 6005 PM6017 7010

3707 3719 5002 6006 PM6018 7011

3708 3720 5003 6007 PM6019 7012

3709 3721 5004 6008 7001 8001

3710 3722 5005 6009 7002 8002

3711 3723 5006 6010 7003 8003

3712 3724 5007 6011 7004 8004

BP14_003_0501EN G1
 Glossary

8005 10005 10017 12001 12013 12025

8006 10006 10018 12002 12014 12026

8007 10007 10019 12003 12015 12027

8008 10008 10020 12004 12016 12028

8009 10009 10021 12005 12017 12029

9001 10010 10022 12006 12018 12030

9002 10011 10023 12007 12019 12031

9003 10012 10024 12008 12020 12032

10001 10013 10025 12009 12021 12033

10002 10014 11001 12010 12022 12034

10003 10015 11002 12011 12023 12035

10004 10016 11003 12012 12024 12036

G2 BP14_003_0501EN
 Glossary

12037 12043 12049 12055 13004 14003

12038 12044 12050 12056 PM13005 15001

12039 12045 12051 12057 PM13006 15002

12040 12046 12052 13001 PM13007 15003

12041 12047 12053 13002 14001

12042 12048 12054 13003 14002

G–1.2 Support (for key, see page G — 10)

2601 2604 2607 2610 2613 2616

2602 2605 2608 2611 2614 2617

2603 2606 2609 2612 2615

BP14_003_0501EN G3
 Glossary

G–1.3 Boom, 2–arm (for key, see page G — 10)

1201 1203 1205 1207 1209 1211

1202 1204 1206 1208 1210

G–1.4 Boom, 3–arm (for key, see page G — 10)

1301 1304 1307 1310 1313 1316

1302 1305 1308 1311 1314

1303 1306 1309 1312 1315

G–1.5 Boom, 4–arm (for key, see page G — 11)

1401 1406 1411 1416 1421 1426

1402 1407 1412 1417 1422 1427

1403 1408 1413 1418 1423

1404 1409 1414 1419 1424

1405 1410 1415 1420 1425

G4 BP14_003_0501EN
 Glossary

G–1.6 Boom, 5–arm (for key, see page G — 12)

1501 1506 1511 1516 1521 1526

1502 1507 1512 1517 1522 1527

1503 1508 1513 1518 1523 1528

1504 1509 1514 1519 1524 1529

1505 1510 1515 1520 1525 1530

G–1.7 Boom, 6–arm (for key, see page G — 12)

PM1601 PM1604 PM1607 PM1610 PM1613 PM1616

PM1602 PM1605 PM1608 PM1611 PM1614

PM1603 PM1606 PM1609 PM1612 PM1615

BP14_003_0501EN G5
 Glossary

G–1.8 Ergonic Boom Control, 3–arm (for key, see page G — 13)

PM1301 PM1303 PM1305 PM1307 PM1309

PM1302 PM1304 PM1306 PM1308

G–1.9 Ergonic Boom Control, 4–arm (for key, see page G — 13)

PM1401 PM1403 PM1405 PM1407 PM1409 PM1412

PM1402 PM1403A PM1406 PM1407A PM1410 PM1413

PM1402A PM1404 PM1406A PM1408 PM1411 PM1414

G–1.10 Ergonic Boom Control, 5–arm (for key, see page G — 14)

PM1501 PM1503 PM1505 PM1507 PM1509 PM1512

PM1502 PM1503A PM1506 PM1507A PM1510 PM1513

PM1502A PM1504 PM1506A PM1508 PM1511 PM1514

G–1.11 Ergonic Boom Control, 6–arm (for key, see page G — 14)

PM1601 PM1603 PM1605 PM1607 PM1609 PM1611

PM1602 PM1604 PM1606 PM1608 PM1610

G6 BP14_003_0501EN
 Glossary

G–2 Key to the symbols for concrete pumps

G–2.1 General
3701 Increase/reduce output using rotarycontroller 5001 Agitator, hopper

3702 Increase/reduce output using toggleswitch 5002 Agitator clockwise rotation

3703 Increase output 5003 Agitator anticlockwise rotation

3704 Reduce output 5004 Hopper empty

3705 Reverse pumping 5005 Hopper full

3706 Pumping On 5006 Agitator cut−out

3707 Pumping Off 5007 Hopper level control

3708 Pumping On−Off 5008 High−pressure agitator

3709 Pumping standby 6001 Hydraulic oil excess temperature

3710 Pumping in general 6002 Radiator

3711 Rotor pump in general 6003 Radiator1

3712 Pump flow meter 6004 Radiator2

3713 Full output 6005 Fill accumulator

3714 Half output 6006 Dump accumulator pressure

3715 High pressure pump 6007 Hydraulic cylinder blockage

3716 Pump control system 6008 High−pressure hydraulic system

3717 Change−over 6009 Insufficient hydraulic fluid

3718 Stroke pulse change−over 6010 Hydraulic fluid

3719 Stroke correction 6011 Air

3720 Change−over delay 6012 High pressure

3721 Screw conveyor1 anticlockwise rotation 6013 Accumulator pressure

3722 Screw conveyor1 clockwise rotation 6014 Filter element

3723 Screw conveyor2 anticlockwise rotation 6015 Rod side

3724 Screw conveyor2 clockwise rotation 6016 Piston side

3725 Screw conveyor PM6017 Hydraulic fluid filter water level STOP

4001 Centralised grease lubrication, manual PM6018 Hydraulic fluid filter water level warning

4002 Centralised grease lubrication, automatic PM6019 Hydraulic fluid filter contamination warning

4003 Centralised oil lubrication, manual 7001 Working light

4004 Centralised oil lubrication, automatic 7002 Lighting

BP14_004_0905EN G7
 Glossary

7003 Control cabinet lighting 10010 Speed sensor

7004 Toolbox lighting 10011 Increase speed

7005 Rear light 10012 Reduce speed

7006 Spirit level lighting 10013 Engine air filter

7007 Flashing beacon 10014 Electric motor in general

7008 Acknowledge flashing beacon 10015 Silent

7009 Brake light 10016 Reduced fuel consumption

7010 Side marker lamps container 10017 Tank monitoring

7011 Lighting mast 10018 Coolant level

7012 Diagnostics lamp 10019 Diesel engine control

8001 Machine diagnostics connector 10020 Starter

8002 Read−out data 10021 Manual throttle lever

8003 Read−in data 10022 Start−up relief (soft start)

8004 Read−in minimum value 10023 Diesel supply On

8005 Reset memory contents (save) 10024 Fuel

8006 Cancel memory contents (clear) 10025 Fuel filter draining

8007 Start 11001 Radio remote control

8008 Read−in maximum value 11002 Remote control in general

8009 Menu 11003 Plug in remote control

9001 Control cabinet 12001 Horn

9002 Diagnostics socket 12002 Fault in general

9003 Teleservice 12003 Acknowledge

10001 Diesel engine On 12004 Battery

10002 Diesel engine Off 12005 Battery charging device

10003 Engine oil excess temperature 12006 EMERGENCY STOP activated

10004 Cooling water excess temperature 12007 Acknowledge EMERGENCY STOP

10005 Acknowledge cooling water excess temperature 12008 Stop

10006 Engine oil pressure 12009 Test operation

10007 V−belt failure 12010 Vibrator On

10008 Increase speed, reduce speed 12011 Vibrator Off

10009 Speed 12012 Vibrator

G8 BP14_004_0905EN
 Glossary

12013 Potentiometer 12042 Lock

12014 Off−On 12043 2ndlevel

12015 On 12044 Circuit1

12016 Off 12045 Circuit2

12017 Fast (e.g.acceleration) 12046 Circuits1+2

12018 Normal (e.g.acceleration) 12047 High−pressure limit

12019 Compressor 12048 Flap/closure closed

12020 Compressor On−Off 12049 Flap/closure open

12021 Motor vehicle fuse 12050 Generator

12022 Cable drum 12051 Boom on cradle

12023 Operating hours meter 12052 Manual operation

12024 Operating position 12053 Electrical levelling

12025 Electrical power 12054 See Operating Instructions

12026 Automatic/manual 12055 Wear measurement

12027 Automatic operation 12056 Water

12028 Close shut−off device 12057 Overhead roll−and−fold boom

12029 Open shut−off device 13001 Power take−off

12030 Water tank heating 13002 Truck in general

12031 Cleaning 13003 Plan view

12032 Levelling control in general 13004 Brake in general

12033 Excess pressure PM13005 Driving

12034 Fuse test PM13006 Lifting axle raised

12035 Timer relay PM13007 Lifting axle not raised

12036 Right side 14001 Mixer in general

12037 Left side 14002 Drain mixer

12038 Concrete brake 14003 Activate mixer

12039 Buzzer 15001 Water glass dosing pump

12040 Container 15002 Flushing water pump

12041 Position at the machine 15003 High−pressure water pump

BP14_004_0905EN G9
 Glossary

G–2.2 Support
2601 Support leg/foot retract/extend 2610 Support leg working light

2602 Extend support leg 2611 Support leg retract/extend

2603 Retract support leg 2612 Support foot retract/extend

2604 Lower support foot 2613 Side marker lamps support leg

2605 Raise support foot 2614 Working range on the right

2606 Swing out right support leg 2615 Working range on the left

2607 Swing in right support leg 2616 Enable stability monitoring

2608 Swing out left support leg 2617 Stability monitoring

2609 Swing in left support leg

G–2.3 Boom, 2–arm

1201 Boom in general 1207 Slew boom to the left

1202 Arm 1 up 1208 Slew boom to the right

1203 Arm 1 down 1209 Move arms

1204 Arm 2 up 1210 Move arms switched off

1205 Arm 2 down 1211 Slewing gear activated

1206 Boom activated

G–2.4 Boom, 3–arm

1301 Boom in general 1309 Slew boom to the left

1302 Arm 1 up 1310 Slew boom to the right

1303 Arm 1 down 1311 Move arms

1304 Arm 2 up 1312 Move arms switched off

1305 Arm 2 down 1313 Slewing gear activated

1306 Arm 3 up 1314 Slew boom to the right switched off

1307 Arm 3 down 1315 Slew boom to the left switched off

1308 Boom activated 1316 Arm1 down switched off

G10 BP14_004_0905EN
 Glossary

G–2.5 Boom, 4–arm

1401 Boom in general 1415 Slewing gear activated

1402 Arm 1 up 1416 Arms up switched off

1403 Arm 1 down 1417 Slew boom to the left switched off

1404 Arm 2 up 1418 Slew boom to the right switched off

1405 Arm 2 down 1419 Arm1 down switched off

1406 Arm 3 up 1420 Arms up switched on

1407 Arm 3 down 1421 Tilt switch, arm1 circuit1

1408 Arm 4 up 1422 Tilt switch, arm1 circuit2

1409 Arm 4 down 1423 Tilt switch, arm2 circuit1

1410 Boom activated 1424 Tilt switch, arm2 circuit2

1411 Slew boom to the left 1425 Pressure switch, arm1 circuit1

1412 Slew boom to the right 1426 Pressure switch, arm1 circuit2

1413 Move arms 1427 Unfolding position

1414 Move arms switched off

BP14_004_0905EN G11
 Glossary

G–2.6 Boom, 5–arm

1501 Boom in general 1516 Move arms

1502 Arm 1 up 1517 Move arms switched off

1503 Arm 1 down 1518 Slew boom to the left switched off

1504 Arm 2 up 1519 Slew boom to the right switched off

1505 Arm 2 down 1520 Arm1 down switched off

1506 Arm 3 up 1521 Arms up switched on

1507 Arm 3 down 1522 Tilt switch, arm1 circuit1

1508 Arm 4 up 1523 Tilt switch, arm1 circuit2

1509 Arm 4 down 1524 Tilt switch, arm2 circuit1

1510 Arm 5 up 1525 Tilt switch, arm2 circuit2

1511 Arm 5 down 1526 Pressure switch, arm1 circuit1

1512 Boom activated 1527 Pressure switch, arm1 circuit2

1513 Slew boom to the left 1528 Unfolding position

1514 Slew boom to the right 1529 Arm5 switched on

1515 Slewing gear activated 1530 Arm5 switched off

G–2.7 Boom, 6–arm

PM1601 Boom in general PM1609 Arm 4 down

PM1602 Arm 1 up PM1610 Arm 5 up

PM1603 Arm 1 down PM1611 Arm 5 down

PM1604 Arm 2 up PM1612 Arm 6 up

PM1605 Arm 2 down PM1613 Arm 6 down

PM1606 Arm 3 up PM1614 Boom activated

PM1607 Arm 3 down PM1615 Slew boom to the left

PM1608 Arm 4 up PM1616 Slew boom to the right

G12 BP14_004_0905EN
 Glossary

G–2.8 Ergonic Boom Control, 3–arm

PM1301 Move end hose PM1306 Unfold the placing boom

PM1302 End hose forwards PM1307 Fold the placing boom

PM1303 End hose back PM1608 End hose to the left

PM1304 End hose up PM1309 End hose to the right

PM1305 End hose down

G–2.9 Ergonic Boom Control, 4–arm

PM1401 Move end hose PM1407 Fold the placing boom

PM1402 End hose forwards PM1407A Fold the placing boom (USA)

PM1402A End hose forwards (USA) PM1408 End hose to the left

PM1403 End hose back PM1409 End hose to the right

PM1403A End hose back (USA) PM1410 Upper limit

PM1404 End hose up PM1411 Lower limit

PM1405 End hose down PM1412 Preferred position for arm 1

PM1406 Unfold the placing boom PM1413 Preferred position for arm 4

PM1406A Unfold the placing boom (USA) PM1414 Preferred position arm1 + arm4

BP14_004_0905EN G13
 Glossary

G–2.10 Ergonic Boom Control, 5–arm

PM1501 Move end hose PM1507 Fold the placing boom

PM1502 End hose forwards PM1507A Fold the placing boom (USA)

PM1502A End hose forwards (USA) PM1508 End hose to the left

PM1503 End hose back PM1509 End hose to the right

PM1503A End hose back (USA) PM1510 Upper limit

PM1504 End hose up PM1511 Lower limit

PM1505 End hose down PM1512 Preferred position for arm 1

PM1506 Unfold the placing boom PM1513 Preferred position for arm 5

PM1506A Unfold the placing boom (USA) PM1514 Preferred position arm1 + arm5

G–2.11 Ergonic Boom Control, 6–arm

PM1601 Move end hose PM1607 Fold the placing boom

PM1602 End hose forwards PM1608 End hose to the left

PM1603 End hose back PM1609 End hose to the right

PM1604 End hose up PM1610 End hose back

PM1605 End hose down PM1611 End hose forwards

PM1606 Unfold the placing boom

G14 BP14_004_0905EN
 Glossary

G–3 Abbreviations and technical terms

ADR Arbeitsdrehzahlregelung → Speed of rotation regulation

Agitator safety cutout The agitator safety cutout automatically cuts power to the agitator
and the concrete pump when the grille is opened.

APP → Automatic Piston Pull

Arc configuration Variant of boom movement in Ergonic Boom Control mode on

machines with a Z fold system: the position of the arm assembly
resembles an arc.

Automatic Piston Pull A ball cock is fitted in the drive cylinder. When the ball cock is
closed, you can pull the delivery piston out of the delivery cylinder
to replace it.

Blockage Blockage in the delivery line: the concrete behind the blockage
cannot continue to flow. The blockage may occur due to wedging
caused by coarse particles, etc.

Change−over Reversal of direction of the delivery piston in the middle of a stroke

movement: The → transfer tube switches over. The concrete is still
pumped without interruption.

Change−over delay throttle The change−over delay throttle is a hydraulic component which
delays the change−over of the → transfer tube.

Check book The check book is part of the documentation accompanying the
machine: checklist with confirmation of the legally required checks
for concrete pumps and placing booms

Corner bearing load The corner bearing load is the force transferred to the ground
through each support foot.

BP14_002_0501EN G15
 Glossary

dB Decibels: unit of measurement for the → sound power level

dB (A) Decibels (A): unit of measurement for the → sound pressure level

EBC → Ergonic Boom Control

EDC → Electronic Diesel Control

EGD → Ergonic Graphic Display

EGD−RC → Ergonic Graphic Display  Remote Control

Electronic Diesel Control Automatic vehicle−specific control of fuel consumption

EOC → Ergonic Output Control

EPS → Ergonic Pump System

Ergonicr Registered brand name for all Putzmeister components which

control concrete pumps and placing booms.

Ergonic Boom Control Microprocessor supported system for controlling and regulating
the placing boom. Among other functions, EBC allows you to move
the placing boom using just one joystick.

Ergonic Graphic Display Graphic display in the control cabinet door. The operating state of
the machine is shown in the display. You may also be able to set
functions here, depending on the equipment on your machine.

Ergonic Graphic Display  Graphic display in the remote control. The operating state of the
Remote Control machine is shown in the display. You may also be able to set
functions here, depending on the equipment on your machine.

Ergonic Output Control Microprocessor supported system for economic operation of

theconcrete pump. The minimum engine speed required for
thedelivery rate selected by the operator is automatically set.

Ergonic Pump System Microprocessor supported system for controlling and regulating
the concrete pump. Among other functions, EPS allows you to
restrict the concrete pressure and delivery rate.

G16 BP14_002_0501EN
 Glossary

FFH → Free−Flow Hydraulics

Free−Flow Hydraulics Free−Flow Hydraulics is a type of drive for the concrete pump
which switches the fluid flow from the main pump directly to the
drive cylinders, i.e. there is free fluid flow without interposed
valves.

Fully hydraulic control Fully hydraulic control is a type of control of the concrete pump
which switches the fluid flow from the main pump to the drive
cylinder using valves (closed hydraulic circuit).

Functional fluids Hydraulic fluid, fuel, brake fluid, battery acid etc.

Grille The grille is the protective cover for the hopper and has two
functions:
− Allowing only particles up to a certain size to pass
− Protecting persons against reaching into the hopper

KEP Kolben−Endlagen−Positionierung → Piston end−of−travel

positioning

Lela → Levelled last arm

Level control Level control controls the amount of concrete in the hopper during
pumping operations using a fill−level sensor.

Levelled last arm Last arm of the placing boom in a horizontal position

BP14_002_0501EN G17
 Glossary

Machine card The machine card is part of the documentation accompanying

themachine:
− List of machine components
− Circuit diagram information

Maintenance card A maintenance card describes measures and their sequence for
maintaining the machine and for replacing parts and wear parts.

Monoblock The monoblock is a hydraulic safety valve on the boom hydraulic

cylinders.

NA / NMV NA and NMV are types of power take−off:

− The NA power take−off is a transmission−dependent PTO.
− The NMV power take−off is independent of the clutch.

One−Side−Support One−Side−Support is a type of support for supporting the machine

in narrow spaces.

Operating equipment Battery, filters

OSS → One−Side−Support

PEDOC → Putzmeister Electronic Documentation

Piston end−of−travel positioning A ball valve is fitted in the drive cylinder. When the ball valve is
closed, you can lock the drive cylinder in its end−of−travel position
to replace it.

Piston side

Proportional control Infinitely variable controller for setting the boom speed

Putzmeister Electronic Documentation accompanying the machine on CD−ROM

Documentation

G18 BP14_002_0501EN
 Glossary

Quick disconnect point Arm 1 of the arm assembly can be disconnected at the quick
disconnect point.

Reversal The concrete is sucked back from the delivery line into the hopper.

Rod side

Roll−and−fold system Type of folding of the arm assembly: the arm is rolled when folded
in and out.

Roll configuration Position of the M 31 arm assembly in Ergonic Boom Control

operation when the end hose is moved within the stored limits.

Rotor pump The rotor pump comprises

− a rotor housing
− a rotor (rotating about its central axis)
− two pressure rollers (running freely)
− a pump tube
The pump tube is pressed together as the pressure rollers roll
overit. This pushes the concrete in the pump tube ahead of
thepressure roller towards the rotor housing outlet and into the
delivery line.

RSA Rührwerksicherheitsabschaltung → Agitator safety cutout

BP14_002_0501EN G19
 Glossary

Service operation The Pumping operations − Service operations" toggle switch

onthe control cabinet can be used to switch over between the
concrete pump and the compressor. You can switch on the
compressor, rather than the pump, at the radio remote control if
you set the switch to Compressor".

Snaplock The snaplock is a mechanical safety device to protect against

unintentional extension and retraction of the support legs.

Sound power level The sound power level is a relative measurement used in acous
tics to indicate the noise emissions from a noise source[dB].

Sound pressure level The sound pressure level is a logarithmic measurement for the
relative loudness of the sound [dB(A)].

Speed of rotation regulation The ADR function regulates the mixer drum speed while the truck
is being driven.

Squeeze valve The squeeze valve is a component on the end hose which closes
the delivery line when the pump is stopped.

Stroke correction The stroke is corrected automatically by the addition or removal of

hydraulic fluid through bores in the cylinder. This means that the
delivery piston can achieve its maximum stroke length. Without
stroke correction, the delivery piston would not always reach its
end position.

Support foot The support foot is a component on the end of the support leg.

Support leg The support leg is a telescopic and/or slewable component for
supporting the machine.

Support foot plate The support foot plate is a component on the underside of the
support foot.

G20 BP14_002_0501EN
 Glossary

Teach−in Specialist word for storing in memory

Test reading The test reading is part of the documentation accompanying the
machine: list of machine setting values

to trigger The magnetic switches are triggered, i.e. when an object is

brought near, they switch without any contact being made.

Transfer tube The transfer tube is a component which is swung between the two
delivery cylinders in the hopper. It is the connection between the
delivery cylinder and the delivery line.

UVD Umsteuer−Verzögerungsdrossel → Change−over delay throttle

VHS Vollhydraulische Steuerung → Fully hydraulic control

Z fold system Type of folding of the arm assembly: the arm assembly resembles
the letter Z when folded in and out.

Z configuration Variant of boom movement in Ergonic Boom Control mode on

machines with a Z fold system: the position of the arm assembly
resembles the letter Z.

BP14_002_0501EN G21
 Glossary

G22 BP14_002_0501EN
Service Instructions
for machine operator and maintenance staff
always keep by the machine

Translation of the original Operating Instructions

Truck–mounted
concrete pump BSF 38–5.16 H NG

Machine no. 214403246

18−09−03

The paper on which this document is printed is 100% chlorine free E Putzmeister Concrete Pumps GmbH 1994
Putzmeister Worldwide

Deutsch Putzmeister Concrete Pumps GmbH +49−7127−599−0 pmw@pmw.de

land Max−Eyth−Strasse 10
PM D− 72631 Aichtal +49−7127−599−520 www.putzmeister.de

España Putzmeister Ibérica S.A. +34−91−428 81 00 recepcion@putzmeister.es

PME Camino de Hormigueras 173
Pol. Ind. Vallecas +34−91−428 81 43 www.putzmeister.es
E− 28031 Madrid
France Putzmeister France +33−164 64 39 39 Infopmf@putzmeister.fr
PMF 3, rue Paul Henri Spaak
ZAE Jean Monnet +33−164 64 39 29 www.putzmeister.fr
77240 Vert Saint Denis
Italia Putzmeister Italia S.r.l. +39−541−85 15 11 putzmeister@putzmeister.it
PMI Via Marconi, 2
I− 47832 San Clemente (RN) +39−541−98 98 59 www.putzmeister.it

Great Putzmeister Limited +44−1246−2642 00 info@putzmeister.co.uk

Britain Carrwood Road
PMUK GB−Chesterfield +44−1246−26 00 77 www.putzmeister.co.uk
Derbyshire S41 9QB
Türkiye Putzmeister Makine Sanayi ve Tic. A.ƞ +90−282−735−1000 pm@putzmeister.com.tr
PTR G.O.PaƟa Mah.
Naműk Kemal Bulvarű No: 6 +90−282−738−1001 www.putzmeister.com.tr
59500 Çerkezköy / TEKŰRDA
USA Putzmeister America +1−262−886−3200 pmr@putzam.com
PMA 1733 90th Street
Sturtevant, WI 53177 USA +1−262−886−3212 www.putzmeister.com

South Putzmeister S.A. (Pty) Ltd. +27−11−794−37 90 pmsa@icon.co.za

Africa Cnr. Bramm & Citrus St. Honeydew
PMSA P.O.Box 5146 ZA 2118 Cresta +27−11−794−41 19 www.putzmeister.co.za
South Africa
India Putzmeister Concrete Machines Pvt Ltd +918326696000 info@pmw.co.in
PCM Plot No. N4, Phase IV
Verna Industrial Estate, Verna Salcete +91832−6696300 www.pmw.co.in
Goa−403722

Japan Putzmeister Japan Ltd. +81−47−553−4140 pmjapan@pm−j.co.jp

PMJ Chiba East Techno Green Park (CETEC)
1−3 Okayamadai, Togane City, +81−47−553−4145 www.putzmeister.de/pmj
Chiba 283 0826, Japan
Korea Putzmeister Korea Co. Ltd. +82−31−433−4541 putzmstr@chollian.net
PMK 1287−1, Chungwang−Dong
Shihwa Ind. 3 da 502 ho, +82−31−498−7230 www.putzmeister.co.Kr
Shihung−city Kyonggi−Do, Korea
P.R.China Putzmeister Machinery Shanghai Co. Ltd +86−21−5774 1000 pmshangh@pu
PMS 39 Dongjing Road blic.sta.net.cn
Songjiang Industrial Zone +86−21−5774 2779 www.putzmeister.com.cn
201613 Shanghai, P.R.China
Russland OOO Putzmeister−Rus +7−495−775−22−37 info@putzmeister.ru
PMR Urgumskaja Straße 4, Geb. 31
129343 Moskau, Russia +7−495−775−22−34 www.putzmeister.ru
 de Übersetzung der Originalbetriebsanleitung
bg Ïðåâîä íà îðèãèíàëíî Ðúêîâîäñòâî çà ðàáîòà
cs Pƙeklad originálního návodu k obsluze
da Oversættelse af den originale driftsvejledning
el MetÜfrash tou prwtotýpou twn odhgiþn leitourgßaj
en Translation of the original Operating Instructions
es Traducción de las instrucciones de servicio originales
et Algupärase kasutusjuhendi tõlge
fi Alkuperäisen käyttöohjeen käännös
fr Traduction des instructions de service originales
hr Prijevod izvornika naputka za uporabu
hu Eredeti üzemeltetési útmutató fordítása
it Traduzione delle istruzioni d’uso originali
lt Eksploatavimo instrukcijos originalo vertimas
lv Lietoơanas pamcbas tulkojums no oriinlvalodas
nl Vertaling van de oorspronkelijke gebruiksaanwijzing
no Oversettelse av original brukerhåndbok
pl TƂumaczenie oryginalnej instrukcji eksploatacji
pt Tradução das Instruções de funcionamento originais
ro Traducerea instrucƣiunilor de funcƣionare originale
ru Gthtdjl abhvtzzjuj herjdjlcndf gj ärcgkefnfwbb
sk Preklad originálneho návodu na obsluhu
sl Prevod izvirnih navodil za uporabo
sv Översättning av original instruktionsbok
tr Orijinal kullanűm kűlavuzunun tercümesi

BP00_030_0911EN
 Tableofcontents

Table of contents
1 Guide to the Service Instructions
1.1 Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 — 1

1.2 Icons and symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 — 3

2 Safety regulations
2.1 Basic principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 1
2.1.1 Exclusion of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  1

2.2 Requirements for special work . . . . . . . . . . . . . . . . . . . . . . . 2 — 2

2.3 Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 4

2.4 Working on the placing boom . . . . . . . . . . . . . . . . . . . . . . . . 2 — 5

2.5 Safety-relevant components . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 5

2.6 Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 6

2.7 Protective and safety equipment . . . . . . . . . . . . . . . . . . . . . 2 — 6

2.8 Electrical power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 7

2.8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  7
2.8.2 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  8
2.8.3 Power at the construction site . . . . . . . . . . . . . . . . . . . . . . . . . . 2  8

2.9 Hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 9

2.9.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  9
2.9.2 Replacing hydraulic hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  10

2.10 Noise emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 10

2.11 Exhaust fumes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 11

2.12 Functional fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 11

2.13 Disposal of the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 12

3 Safety equipment
3.1 Overview of the safety equipment . . . . . . . . . . . . . . . . . . . . 3 — 1
3.1.1 Active safety functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  1

214403175 I
 Tableofcontents

3.1.2 Passive safety function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  1

3.1.3 Organizational measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  1
3.1.4 Safetyrelated parts (SRPs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  2
3.1.5 Safety components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  3
3.1.6 Parts with increased maintenance requirements . . . . . . . . . 3  3

3.2 EMERGENCY STOP function . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 4

3.2.1 Description ofthefunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  4
3.2.2 Function check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  5

3.3 Agitator safety cutout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 6

3.3.1 Description of the functions . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  7
3.3.2 Function check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  8
3.3.3 Acknowledge the agitator safety cutout . . . . . . . . . . . . . . . . . 3  9

3.4 Support control block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 10

3.4.1 Description ofthefunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  10
3.4.2 Function check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  11

3.5 Remote control/boom control block joysticks . . . . . . . . . 3 — 12

3.5.1 Joystick function description . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  12
3.5.2 Function description for boom control block . . . . . . . . . . . . . 3  13
3.5.3 Function check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  14

3.6 Protective devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 16

3.6.1 Description ofthefunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  16
3.6.2 Function check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  16

3.7 Grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 18
3.7.1 Description ofthefunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  18
3.7.2 Function check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  19

3.8 Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 20
3.8.1 Description ofthefunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  20
3.8.2 Function check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  20

II 214403175
 Tableofcontents

4 Special modes of operation

4.1 Emergency operation – pump function . . . . . . . . . . . . . . . 4 — 1

4.2 Emergency operation of the agitator and water pumps . 4 — 3

4.3 Boom control block (emergency control lever for boom functions)
4 —5
4.3.1 Example illustration of a boom control block . . . . . . . . . . . . . 4  6

4.4 Recovering the machine after faults occur . . . . . . . . . . . . 4 — 7

4.4.1 Recovery with onboard equipment . . . . . . . . . . . . . . . . . . . . . 4  8
4.4.2 Recovery with an external hydraulic power pack . . . . . . . . . 4  13

5 Maintenance
5.1 Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 — 1

5.2 Residual risks during maintenance, inspection and repair work

5 —4
5.2.1 Personal protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . 5  4
5.2.2 Personnel requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  4
5.2.3 Auxiliary devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  4
5.2.4 Residual risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  5

5.3 General tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 — 7

5.3.1 Set screws and nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  7
5.3.2 Flared screwed joint, reassembly . . . . . . . . . . . . . . . . . . . . . . . 5  8
5.3.3 Profiled ring joint, reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 5  8

5.4 Functional fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 — 9

5.4.1 Hydraulic fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  9
5.4.2 Level of contaminant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  11
5.4.3 Lubricant analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  11
5.4.4 Storage of lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  11

5.5 Lubricant recommendation . . . . . . . . . . . . . . . . . . . . . . . . . . 5 — 12

5.5.1 Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  14
5.5.2 Greases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  15
5.5.3 Hydraulic fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  16

214403175 III
 Tableofcontents

Maintenance cards
00−001 Visual checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  19
01−021 Transfer gearboxes G64SB and G64SC . . . . . . . . 5  21
01−028 Slewing gear transmission . . . . . . . . . . . . . . . . . . . 5  27
01−020 Inspecting, cleaning and lubricating the cardan shaft 5
 31
03−001 Changing the hydraulicfluid . . . . . . . . . . . . . . . . . . 5  35
03−002 Function checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  41
04−002 Hydraulic hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  43
04−014 Changing the ventilation filter element . . . . . . . . . 5  47
04−018 Hydraulic fluid filter change . . . . . . . . . . . . . . . . . . 5  51
06−047 Delivery piston replacement on the dual piston end−of−tra
vel positioning system . . . . . . . . . . . . . . . . . . . . . . . 5  61
07−001 Lubricating the Stransfertube . . . . . . . . . . . . . . . . 5  71
07−068 Replacing the transfer tube bearing . . . . . . . . . . . 5  73
07−070 Replacing the switching shaft bearing (flanged bearing) .
5 81
07−071 Replace the spectacle wear plate . . . . . . . . . . . . . 5  97
07−072 Replacing the Stransfertube . . . . . . . . . . . . . . . . . 5 111
07−073 Replacing the Stransfertube wear sleeve . . . . . 5 119
07−074 Replacing the thrust ring and wear ring . . . . . . . . 5 127
07−075 Adjusting the Stransfertube . . . . . . . . . . . . . . . . . 5 133
10−007 Measuring the wall thickness (Machines with Stransfer
tube) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 147
10−044 Measuring the wall thickness of two−layer pipes 5 153
20−074 Lubricating the placing boom (M38RZ) . . . . . . . 5 155
21−058 Lubricating the boom pedestal (TRDI80) . . . . . . 5 157
21−001 Checking connecting bolts on the slewing ring . 5 159
25−001 Replacing the delivery line . . . . . . . . . . . . . . . . . . . 5 161

6 Index of key words

IV 214403175
 1 Guide to the Service Instructions

This chapter contains notes and information that will help you to use
these Service Instructions. Do not hesitate to contact us if you have
any queries:

Putzmeister Türkiye
Putzmeister Makine Sanayi Ve Ticaret A.S.
G.O.Pasa Mah. Namik Kemal Bulvari No:6
59500 Çerkezköy/Tekirdag
Telefon +90 282 735 10 00
Fax +90 282 735 10 01
e−mail: pm@putzmeister.com.tr
Hastane Mah. Hadimköy Istanbul Cad. No:62
Hadimköy / Arnavutköy Istanbul
Telefon: +90 212 771 55 00 (6hat)
Fax +90 212 771 55 09
or contact the branch or works agency that is responsible for you.

Address:

Telephone:

Fax:

Email:

TC01_009_1409EN
 GuidetotheServiceinstructions

1.1 Foreword The Service Instructions contain important information about the
maintenance of the machine. Observing these instructions helps to
avoid danger, to reduce repair costs and downtimes, and to increase
the reliability and service life of the machine.

The Service Instructions must be supplemented by the relevant

national rules and regulations for accident prevention and environ
mental protection.

The Service Instructions must always be available wherever the ma

chine is in use.

These Service Instructions must be read and applied by any person

in charge of carrying out work with or on the machine, e.g.
− in operation, including setting up, fault rectification in the course of
work, removal of production waste, care and disposal of fuels and
consumables;
− maintenance (servicing, inspection, repair) and/or
− Transport
.

In addition to the Service Instructions and mandatory rules and re

gulations for accident prevention in the country and place of use of
the machine, the generally recognized rules of technology for safe
and proper working must be observed.

BP01_010_1011EN 11
 GuidetotheServiceinstructions

Should you have any questions after studying the Service Instruc
tions, the branch or agency serving you, or the Aichtal Works, will be
happy to provide you with more information.

You will make it much easier for us to answer any questions if you
can give us the details of the machine model and the machine
number.

These Service Instructions describe the vehicle superstructure only.

The Operating Instructions issued by the vehicle manufacturer apply
for the vehicle itself.

In the interests of constant improvement, modifications are made

from time to time and it may be the case that we were unable to take
these into consideration when these Service Instructions were
printed.

In the event of any amendment, the copy of the Service Instructions

that is intended for the machine will be replaced in full.

The reproduction, distribution and utilization of this document as well

as the communication of its contents to others without explicit author
ization is prohibited. Offenders will be held liable for the payment of
damages. All rights reserved in the event of the grant of a patent,
utility model or design.

© Putzmeister Concrete Pumps GmbH 1994

12 BP01_010_1011EN
 GuidetotheServiceinstructions

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

" Task symbol

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

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

See also the maintenance cards:

This icon is used to refer to the maintenance cards required,
possibly as a supplement to the maintenance card you are currently
reading.

The following special tools are required:

This icon identifies the special tools necessary to carry out the work.
Normal tools, i.e. commercially−available tools or tools carried in the
truck, are not specially listed.

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

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

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

BP01_003_0601EN 13
 GuidetotheServiceinstructions

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

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

of the danger precisely.

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

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

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

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

14 BP01_003_0601EN
 GuidetotheServiceinstructions

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

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

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

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

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

BP01_003_0601EN 15
 2 Safety regulations

These safety regulations conform to the chapter Maintenance and

special work" in the VDMA brochure

Safety manual Concrete delivery and placing machines".

The safety regulations in the Operating Instructions must also be fol

lowed for all maintenance and special work.

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

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

information:
 EN12001, Conveying, spraying and placing machines for con
crete and mortar
 EN12100, Safety of machinery,
 EN602041, Electrical equipment of machines.
 in the Federal Republic of Germany: BGR182, Concrete pumps
and placing booms.

BP03_083_1011EN
 Safetyregulations

2.1 Basic principle The safety regulations in the Operating Instructions for this machine
apply whenever the machine is operated.

Danger
There is an increased risk of accidents during a special operation.
You may only carry out the activities described in these service in
structions if:
 you have been trained for these activities by the machine manu
facturer
 you have been authorized for these activities by the machine oper
ating company

2.1.1 Exclusion of liability We state here expressly that Putzmeister accepts no liability for dam
age arising from incorrect or negligent operation, servicing or main
tenance or as a result of use contrary to the designated use. This
statement is particularly valid for modifications to, additions to and
customization of the machine that are liable to compromise safety.
The guarantee will no longer be valid in such cases.

BP03_084_1011EN 21
 Safetyregulations

2.2 Requirements In the capacity of operator, it is your responsibility to provide all the
for special work necessary information to the personnel concerned before special
work or maintenance work is carried out. Someone should be nomi
nated as the person responsible for this.

Carry out the maintenance and inspection operations and comply

with intervals specified in the Operating Instructions, including spec
ifications for the replacement of parts and equipment. These acti
vities must be carried out by qualified personnel only.

Workshop equipment appropriate to the task in hand is absolutely

necessary for the execution of maintenance work.

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

necessary.

A machine completely shut down for maintenance and repair work

must be secured against being restarted inadvertently:
− Lock the main control devices and remove the key.
− If a main switch is fitted, attach a warning plate to it.

Only carry out maintenance work if the machine is parked on level

and sufficiently supporting ground and is secured against rolling
away.

Use specially designed or otherwise safety−oriented climbing aids

and working platforms when carrying out assembly work above head
height. Never use machine parts as climbing aids. Keep all hand
grips, steps, railings, platforms and ladders free from dirt, snow and
ice.

22 BP03_085_1401EN
 Safetyregulations

Carefully secure individual parts and large assemblies to lifting gear

when carrying out a replacement operation. Use only suitable and
technically perfect lifting gear and suspension systems with ad
equate lifting capacity. Never stand under suspended loads.

The fastening of loads and instruction of crane operators should be

entrusted to experienced persons only. The signaller must be within
visual range of or in voice contact with the crane operator.

Observe national regulations when working with lifting gear.

Work on chassis, braking and steering systems must only be carried

out by qualified personnel trained for such work.

Clean the machine, especially connections and threaded unions, of

any traces of oil, fuel or preservatives before carrying out mainten
ance or repair work. Do not use aggressive cleaning agents. Use
lint−free cleaning rags.

Bolted connections that you have loosened for carrying out mainten
ance and repair work must always be retightened to the specified
torque.

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

flaps, for instance. The spring elements are filled with gas under high
pressure which can escape explosively if you attempt to open them.
Relieve the tension on systems under mechanical stress.

Be aware of hot functional fluids and surfaces (hydraulic fluid, hy

draulic fluid radiator, etc.).

Ensure that all functional fluids, consumables and replaced parts are
disposed of safely and with minimum environmental impact.

BP03_085_1401EN 23
 Safetyregulations

2.3 Welding Only qualified personnel commissioned by the manufacturer may

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

Always attach the earth cable of the welding unit directly to the com
ponent which is being welded. The welding current must not flow
through hinges, cylinders, etc. Significant damage may be caused
by current bridging gaps.

wz0215

Electronic components can be destroyed by stray voltage during arc

welding processes. For this reason:
− Disconnect the remote control cable from the control console.
− Disconnect all cables leading to the receiver of the radio remote
control system.
− Close connector sockets with caps.
− Disconnect the positive and negative leads from the battery.

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

Clean the machine and its surroundings of dust and flammable sub
stances and make sure that the premises are adequately ventilated
before carrying out welding, flamecutting and grinding operations
(danger of explosion).

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

24 BP03_085_1401EN
 Safetyregulations

2.4 Working on the Only carry out maintenance and repair work on the placing boom if
placing boom the placing boom is folded or properly supported, the engine is
switched off and the support legs are secured.

Support the placing boom arms before starting work on the valves,
cylinders or hydraulic lines on the boom.

The delivery line was installed without tension with the placing boom
in the driving position and can only be replaced without difficulty in
this condition. Stresses may be generated on folding if the delivery
line is replaced when the placing boom is unfolded.

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

Following substantial changes, placing booms must be inspected by

an authorized inspector before recommissioning.

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

Parts relevant to safety and adjustable devices (pressure limiting

valve, potentiometer, fluid flow limiter, hydraulic cylinders, etc.) must
only be repaired, replaced or adjusted by After Sales Service per
sonnel. Seals must only be removed by the manufacturer’s After
Sales Service personnel. Modifications to the machine data (in par
ticular, increasing pressures, modifying speeds, etc.) are not per
mitted.

BP03_085_1401EN 25
 Safetyregulations

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

Only persons authorized by the manufacturer may intervene in the

machine’s software. This also applies to updates.

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

vere damage and accidents.

2.7 Protective and Any safety devices removed for maintenance purposes must be re
safety equipment fitted and checked immediately upon completion of this work.

All equipment required for safety and accident prevention (warning

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

Keep all warning signs and information plates on the machine com
plete and in a perfectly legible condition.

It is your responsibility as operator to ensure that any warning signs

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

26 BP03_085_1401EN
 Safetyregulations

2.8 Electrical power

2.8.1 General Work on electrical systems or operating equipment must only be car
ried out by qualified personnel. For further information on machines
operated on the site power supply, see also section2.8.3,entitled
Power at the construction site".

Machine components which are to undergo maintenance work must

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

Disconnect the negative lead from the battery before starting any
work on the electrical system of machines with an internal combus
tion engine. When reconnecting, connect the positive terminal first,
and then the negative terminal.

Before starting work on highvoltage assemblies and after cutting the

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

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

person is required who can switch off the power supply to the ma
chine in the event of an emergency. Secure the working area with a
red−and−white safety chain and a warning plate. Use insulated tools
only.

BP03_085_1401EN 27
 Safetyregulations

2.8.2 Electrical components Control cabinet, motor and control elements are protected as stan
dard at least to degree of protection IP54. IP54 means:
− Complete protection against contact with live components or inter
nal moving parts. Protection against damaging dust deposits.
− Water spraying on the equipment from random directions shall not
have a damaging effect.

Use only original fuses with the specified current rating. The electri
cal system can be destroyed by overrated fuses or bridging. You
must switch off the machine immediately if a fault occurs in the
power supply.

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

Only qualified personnel may work on electrical systems with an op

erating voltage in excess of 25volts alternating voltage or 60volts
direct current. Only such qualified personnel may install, connect,
disconnect and open electrical control cabinets.

An electric shock (possibly with fatal consequences) may be the re

sult of touching machines with electric motors or contact with other
electrical cables if the electrical connection has not been made
properly or the supply cable is damaged.

28 BP03_085_1401EN
 Safetyregulations

2.9 Hydraulic systems

2.9.1 General Work on hydraulic systems must only be carried out by qualified per
sonnel.

Always wear your personal protective equipment when carrying out

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

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

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

Parts of the system and pressure lines which are to be opened (hy
draulic, pneumatic, and delivery lines) must be depressurized ac
cording to assembly descriptions before repair work is started.

Work only on depressurized systems. Switch the hydraulic pump

drive and the engine off, otherwise there is a risk of injury caused by
functional fluids escaping under pressure. Where a hydraulic accu
mulator is fitted, open the accumulator dump valve to prevent any
movements of the machine as a result of the residual pressure.
Modifications to the hydraulic accumulator are prohibited.

Be aware that enclosed hydraulic fluid can remain under pressure

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

Route and install hydraulic lines in accordance with current engin

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

BP03_085_1401EN 29
 Safetyregulations

You must carefully bleed the hydraulic system after any maintenance
work, otherwise there is a risk of injury caused by swinging and tele
scopic support legs extending rapidly, the placing boom lowering,
etc. Open vent valves very carefully until hydraulic fluid starts to es
cape. You should on no account open vent valves further than
necessary or go so far as to remove them.

Damaged hydraulic lines must be replaced rather than repaired. You

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

2.9.2 Replacing hydraulic During retesting, hydraulic hoses must be checked by a subject ex
hoses pert for outer damage. The retest must be recorded in the check
book. The operator must have hydraulic hoses replaced if they show
signs of external damage.

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

Wear suitable personal protective equipment in the vicinity of the ma

chine.

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

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

All soundproofing equipment must be fitted and in perfect condition.

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

210 BP03_085_1401EN
 Safetyregulations

2.11 Exhaust fumes Vehicle exhaust gases contain constituents which can be lethal or
carcinogenic. Operate internal combustion engines and fuel−oper
ated heating systems only in adequately ventilated premises. Before
starting up the engine in enclosed spaces, make sure that there is
adequate ventilation and direct the exhaust gases away from the
place of work.

Wear personal protective clothing and equipment for all work in

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

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

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

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

wz0146

Take care when handling toxic and caustic functional fluids (brake
fluid, battery acid, water glass, concrete set accelerating admix
tures, cement, etc.). Building materials containing cement have a
highly alkaline effect when they react with water (and also with per
spiration). Admixtures are toxic and caustic.

BP03_085_1401EN 211
 Safetyregulations

Cleaning agents, concrete release agents, preserving agents etc.

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

Frequent injuries are eye injuries caused by concrete spatter, water

glass or other chemical substances.

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

Have used operating equipment and functional fluids such as filters,

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

wz0186

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

212 BP03_085_1401EN
 3 Safety equipment

The safety equipment on the machine is described in this chapter. In

particular, it contains information about
− Intervals for inspection by subject experts
− Intervals for function checks

BP15_001_1202EN
 Safetyequipment

3.1 Overview of the Depending on the type of machine and its equipment, the following
safety equipment safety equipment may be fitted. Please see the machine card for
details about which safety equipment your machine has been fitted
with. Carry out checks on the existing safety equipment according to
the following descriptions within the specified intervals.

3.1.1 Active safety functions

Interval for inspection Interval for function check

by a subject expert
EMERGENCY STOP function annually before the machine is used
each time
Agitator safety cutout annually before the machine is used
each time
Support control block annually before the machine is used
each time
Joysticks for remote control/ annually before the machine is used
boom control block each time

3.1.2 Passive safety function

Interval for inspection Interval for function check

by a subject expert
Separating protective annually each time a separating
devices protective device is removed
Grille annually once a month

3.1.3 Organizational measures

Interval for inspection Interval for function check

by a subject expert
Plates annually once a month

BP15_003_1202EN 31
 Safetyequipment

3.1.4 Safety-related parts (SRPs)

Safetyrelated parts (SRP) are components that ensure the safety

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

Danger
If an SRP is not properly maintained, repaired or replaced, this may
cause safety functions to malfunction. This creates a lethal danger.
An SRP must only be maintained, repaired or replaced by qualified
personnel who have been authorized by Putzmeister.

SRP marking

BP15_003_1202EN 1

Spare parts sheet Spare part packaging

32 BP15_003_1202EN
 Safetyequipment

3.1.5 Safety components

The following listed parts are defined as safety components.

Thisincludes the following components in particular:
− loadholding valves (monoblock, duoblock)
− pressure limiting valves

Danger
If a safety component is not properly maintained, repaired or
replaced, this may cause safety functions to malfunction.
Thiscreates a lethal danger. A safety component must only be
maintained, repaired or replaced by qualified personnel who have
been authorized by Putzmeister.

3.1.6 Parts with increased maintenance requirements

The following listed parts are defined as parts with increased main
tenance requirements. This includes the following components in
particular:
− accumulator
− accumulator bladder
− gas valve insert for accumulator

Danger
If a component with increased maintenance requirements not
properly maintained, repaired or replaced, this may cause safety
functions to malfunction. This creates a lethal danger. A component
with increased maintenance requirements must only be maintained,
repaired or replaced by qualified personnel who have been author
ized by Putzmeister.

BP15_003_1202EN 33
 Safetyequipment

3.2 EMERGENCY STOP function

ISO138491:2006 category1 PLc

Intervals for inspection by a
annually
subject expert
Intervals for function checks Before the machine is used each time

3.2.1 Description As soon as an EMERGENCY STOP button is pressed, all dangerous

of the functions machine movements stop. The following actions are triggered when
the relevant components are present on the machine:

System Safety action

Pump − The accumulator dump valve is opened and the

accumulator is emptied.
− The agitator stops.
− The transfer tube stops.
Boom and − The boom control block is disconnected.
support legs − The boom and support leg control do not work.
Mixer drum − The hydraulic pump control chambers are
switched at the same pressure.
− The mixer drum stops.
Rotor pump − The hydraulic pump control chambers are
switched at the same pressure.
− The rotor pump stops.
Remote con- − The supply voltage to the entire radio remote
trol control system is switched off, all indicator
lamps on the radio remote control unit go out.
− The EGDRC switches off.
− The supply voltage, apart from the horn, is
switched off at the cable remote control system,
and the Fault" indicator lamp is lit on the cable
remote control unit.

34 BP15_004_1202EN
 Safetyequipment

System Technical action

Truck − Engine speed drops to idle.

− It is no longer possible to set the engine speed
electrically.
Pump − The EMERGENCY STOP" symbol flashes on
the EGD.
− Variable main pumps swing back, the delivery
pistons come to a halt.

3.2.2 Function check It is only possible to intervene rapidly in the event of danger if all the
EMERGENCY STOP buttons are functioning.

" Switch the pump and agitator on.

" Operate a boom function.

" Press one of the EMERGENCY STOP buttons.

å The agitator and the boom must come to a halt immediately.
å The accumulator is emptied.

" Check all EMERGENCY STOP and STOP buttons on the ma
chine and on the remote control in the same way.

BP15_004_1202EN 35
 Safetyequipment

3.3 Agitator safety cutout

ISO138491:2006 category1 PLc

Intervals for inspection by a
annually
subject expert
Intervals for function checks Before the machine is used each time

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

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

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

You must stop work if you open the grille, but

 the agitator continues to run, or
 the transfer tube continues to switch over, or
 the concrete pump does not run to its end position.

36 BP15_012_1209EN
 Safetyequipment

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

1 2 3

BP15_012_1209EN 1

No. 0 Designation
1 Reading head (on the hopper − example illustration)
2 LED, green and red
3 Transponder (in the grille)

Safety action:
− The accumulator dump valve is opened and the accumulator is
emptied.
− The agitator stops.
− The transfer tube stops.

Technical action:
− The delivery pistons return to the end position.
− The concrete pump stops.

BP15_012_1209EN 37
 Safetyequipment

3.3.2 Function check

BP15_012_1209EN 2

" Open the grille with the concrete pump running.

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

Safety action:
å The agitator must come to a halt immediately.
å The hydraulic fluid pressure in the accumulator is dumped
(see the pressure gauge).
å The transfer tube must no longer switch over.

Technical action:
å The concrete pump must run to the end position and halt.

Hopper type Opening [mm]

RS90x 140
RS907L 210
TMP62CS 159
TMP64Q 89
RS401 40

38 BP15_012_1209EN
 Safetyequipment

3.3.3 Acknowledge the The agitator is secured against unexpected restarts. When the ma
agitator safety cutout chine is set up, and when the agitator safety cutout is triggered, it
must be acknowledged before the concrete pump can be switched
back on.

Danger
Risk of injury when the agitator is operating and the transfer tube is
switching. Before acknowledging the agitator safety cutout, check
that noone is in any danger.

Note
You must acknowledge the agitator safety cutout and switch the con
crete pump off and back on again to restart it.

BP15_012_1209EN 3

No. 0 Designation
1 Acknowledge the agitator safety cutout

" Activate the Acknowledge the agitator safety cutout" toggle

switch.

BP15_012_1209EN 39
 Safetyequipment

3.4 Support control block

ISO138491:2006 category1 PLc

Intervals for inspection by a
annually
subject expert
Intervals for function checks Before the machine is used each time

3.4.1 Description The support control block is designed as an enabling function, i.e. to
of the functions execute a function, you must operate the preselect lever and the
corresponding function lever simultaneously. The hydraulic support
valves are springloaded, i.e. the valves are automatically reset to
the zero position when you release the levers.

Example

2 3 4 5
22104901

No. 0 Designation
1 Preselect lever for support function ON/OFF
2 Raise and lower forward support foot
3 Raise and lower rear support foot
4 Extend and retract forward support leg
5 Swing rear support leg out and in
6 EMERGENCY STOP button

310 BP15_006_1202EN
 Safetyequipment

3.4.2 Function check You can only support the machine correctly when the control block
support is fully functional.

Precondition
− Machine in driving position
− Parking brake applied
− Engine running
− Power takeoff switched on
− Support leg unlocked
− Remote control support function switched on

Execution

Note
Once a lever has been released, the valve must reset to the zero
position of its own accord.

" Extend or swing all support legs approximately halfway out,

one after the other.
å The relevant support leg must stop moving as soon as you
release one of the levers.

" Extend each of the support feet slightly, one after the other.
å The relevant support foot must stop moving as soon as you
release one of the levers.

" Only operate the support function preselect lever.

å The support legs and feet must not move.

" One after another, press each individual support leg valve in
both directions without operating the preselect lever.
å The support legs and feet must not move.

BP15_006_1202EN 311
 Safetyequipment

3.5 Remote control/boom control block joysticks

ISO138491:2006 category1 PLc

Intervals for inspection by a
annually
subject expert
Intervals for function checks Before the machine is used each time

3.5.1 Joystick function The remote control joysticks are devices with selfacting resets
description (switches). As soon as you release a deflected joystick, it is auto
matically reset to the zeroposition.

BP15_007_1202EN 1

No. 0 Designation
1 Joystick

312 BP15_007_1202EN
 Safetyequipment

3.5.2 Function description The boom control block is designed as an enabling function, i.e. for
for boom control a function to be executed, the remote control signal operates the op
block erating mode selector valve and the corresponding boom section
valve at the same time. The hydraulic boom section valves are
springloaded, i.e. the valves are automatically reset to the zero posi
tion when you release the remote control joystick.

Example diagram of
aboom control block

1
2

BP15_007_1202EN 2

No. 0 Designation
1 Input module
2 Operating mode selector valve
3 Boom section valve

BP15_007_1202EN 313
 Safetyequipment

3.5.3 Function check The machine can only be operated safely if the remote control and
boom control block are fully functional.

Note
Perform the function check with both the radio and cable remote
controls.

If you are using the cable remote control, the operating mode selec
tor valve responds with a delay of approx.1second.

Precondition
− Parking brake applied
− Power takeoff switched on
− Machine fully supported
− Engine running

Execution

" Switch on the remote control.

" Raise the arm assembly a few metres.

" Operate the boom control joysticks briefly several times while
observing the valves on the boom control block.
å The boom section valve being actuated and the operating
mode selector valve should move.
å The relevant LED should light up in the corresponding co
lour (see the table below).

" Release the joystick after each function.

å The joystick should reset to the zero position of its own ac
cord.
å The boom section valve and operating mode selector valve
should reset to the zero position of their own accord.

314 BP15_007_1202EN
 Safetyequipment

5
4
3
2
1
BP15_007_1202EN 3

No. 0 Designation
1 Boom section valves arms up−down
2 Rotate the boom section valve
3 Operating mode selector valve
4 Input module
5 LED

LED colours

Function LED
Support leg function red
Boom function green
Slew boom to the left green
Slew boom clockwise red
Arms up red
Arms down green

BP15_007_1202EN 315
 Safetyequipment

3.6 Protective devices

ISO138491:2006 category1 PLc

Intervals for inspection by a
annually
subject expert
Intervals for function checks Before the machine is used each time

3.6.1 Description A protective device is an obstacle (e.g.cover) located between the

of the functions machine operator and the danger zone.

3.6.2 Function check Below you will see a sample diagram of a truckmounted concrete
pump and the protective devices installed.

" Check whether the protective devices are present, fully func
tional and securely mounted.

316 BP15_008_1202EN
 Safetyequipment

1 2 3 4 5 6 7 8 3 9 10 11 12 13

BP15_008_1202EN 1

No. 0 Safety devices

1 Cardan shaft cover
2 Snaplock on the support leg
3 Fourpoint bearing/slewing ring cover
4 Diagonal box/support leg covers
5 Side underride protection
6 Retaining rope on the end hose
7 Securing cotter pins on delivery line couplings
8 Water box cover
9 Boom cradle cover
10 Cover over the switch cylinders
11 Spray guard on the hopper
12 Grille
13 Rear underride protection
Not illustrated:
Catch basket (for cleaning with compressed air)
Protective bell (for divided end hose)
Grille over the fan wheel on the compressor

BP15_008_1202EN 317
 Safetyequipment

3.7 Grille

ISO138491:2006 category2 PLd

Intervals for inspection by a
annually
subject expert
Intervals for function checks Once a month
As soon as a bar has a residual material thickness of 50% of
Intervals for replacement
height or width, at any point.

3.7.1 Description The grille is a passive safety function (protective device). For techni
of the functions cal reasons, the bar spacing is selected in such a way that allows
concrete with defined particle sizes to flow into the hopper. The bars
are subject to natural wear.

Danger
If the grille is defective, there is a risk that the operator could be
caught in the agitator and seriously injured. Therefore, make sure
that the grille remains fully functional at all times. If the residual ma
terial thickness is reached, you must have the grille replaced by
qualified personnel authorized by Putzmeister.

Once the grille has been replaced, the agitator safety cutout must be
reset. This may only be performed by qualified personnel authorized
by Putzmeister.

318 BP15_009_1202EN
 Safetyequipment

3.7.2 Function check

BP15_009_1202EN 1

" Measure the width(W) and height(H) of the bars in an area

with high wear, preferably in the middle of the grille.

" Measure the width(W) and height(H) of the bars in an area

with low wear (the edge of the grille).

" Compare the values measured.

Note
You must have the grille replaced if one of the residual material thick
nesses is less than 50% of the original material thickness.

" Inspect the grille for any other damage (broken bars, cracked
seams, etc.).

Note
You must have the grille repaired or replaced if you detect any dam
age.

BP15_009_1202EN 319
 Safetyequipment

3.8 Plates

Intervals for inspection by a

annually
subject expert
Intervals for function checks Once a month

3.8.1 Description Plates on the machine warn operators of dangers that cannot be pre
of the functions vented by means of the design.

Note
You will find the locations of the plates on the machine circuit dia
grams, which indicate which plate should be affixed where.

3.8.2 Function check

" Check whether the plates that are required according to the
plate location plan have been affixed on the machine and are
legible.

" Replace any missing, damaged or illegible plates with new

ones.

320 BP15_010_1202EN
 4 Special modes of operation

The machine’s special operating modes are described in this

chapter. Special operating modes are, in particular:
− Operation in situations of increased risk
− Operation with limited functions

Danger
There is an increased risk of accidents during special operations.
Special operations must only be carried out if:
 you have been trained for these activities by the machine manu
facturer
 you have been authorized for these activities by the machine oper
ating company

BP16_001_1202EN
 Specialmodesofoperation

4.1 Emergency operation The hydraulic control valves are built into the pump control system.
– pump function They are only for emergency manual operation of the machine when
the control system fails.

1
2
3
4
5

BP16_008_1208EN 1

No. 0 Designation
1 Accumulator
2 Agitator and water pump control block
3 Transfer tube changeover valve
4 Delivery cylinder emergency control lever
5 Transfer tube damping cock
6 Accumulator dump valve

BP16_008_1208EN 41
 Specialmodesofoperation

Special features of the pump control system

Accumulator dump This machine is fitted with an electrically operated agitator safety
valve cutout. The accumulator pressure is dumped through an accumula
tor dump valve and the transfer tube halts, among other measures,
as soon as the grille is opened.

Delivery cylinder If the control system fails, you can operate the delivery cylinders
emergency control using the emergency control lever.
lever
Agitator and water The location of the control block depends on the machine. A de
pump control block scription of emergency operation can be found on the following
pages.

42 BP16_008_1208EN
 Specialmodesofoperation

4.2 Emergency operation You can operate the agitator and the water pumps manually from the
of the agitator and hydraulic control block illustrated below if the control panel has
water pumps failed.

4
2

BP16_003_1209EN 1

No. 0 Designation
1 Agitator/water pumps shutoff valve
2 Agitator changeover valve
3 Water pump emergency operation
4 Direction of agitator rotation emergency operation
5 Agitator emergency operation

BP16_003_1209EN 43
 Specialmodesofoperation

Special features of the hydraulic control block

Flushing water pump To operate the flushing water pump in emergency operation mode,
emergency operation hold down the water pumps emergency operation control on the
shutoff valve.

Note
To operate the highpressure water pump (optional) in emergency
operation mode, you must also hold down the emergency operation
valve on the highpressure water pump.

Agitator emergency To operate the agitator in emergency operation mode, hold down the
operation agitator emergency operation control on the shutoff valve. To
change the direction of rotation, you must also hold down the agita
tor changeover valve.

44 BP16_003_1209EN
 Specialmodesofoperation

4.3 Boom control block The arm assembly can be operated manually at the boom control
(emergency control block in the event of a remote control malfunction.
lever for boom func-
tions)
Danger
Lock the stowage compartment to ensure that unauthorized persons
are not able to gain access to the boom control block.

Arm assemblies with slewing gear transmissions have no mechan

ical stop to limit turning. If the arm assembly is turned too far with the
emergency control levers, the hydraulic hoses of the arm assembly
will wrap around the slewing head and rip off. When turning the arm
assembly with the emergency control levers, always pay attention to
the hydraulic hoses of the arm assembly.

BP16_004_1304EN 45
 Specialmodesofoperation

4.3.1 Example illustration of a boom control block

Note
Depending on the mounting position, the boom functions control
block operating levers may point up or down. The lever assignment
sequence may also be from right to left or vice versa. It may also be
the case that the control block is installed rotated through 90°. Famil
iarize yourself with the functions of the control block by reading the
attached notices.

1 2 3 4 5 6 7
BP16_004_1304EN 1

No. 0 Designation
1 Support or boom function On−Off
2 Slew boom anticlockwise/clockwise
3 Arm1 up−down
4 Arm2 up−down
5 Arm3 up−down
6 Arm4 up−down
7 Arm5 up−down

46 BP16_004_1304EN
 Specialmodesofoperation

4.4 Recovering the If a fault occurs on the machine and cannot be rectified immediately,
machine after faults you must stop site use and take steps to recover the machine.
occur Thedelivery system may become damaged if concrete sets in it.

Note
Recovery of the machine is a special operating mode. The method
described below is not suitable for continuing site use.

Danger
There is an increased risk of accidents during a special operation.
Aspecial operation must only be carried out if:
 you have been trained for these activities by the machine
manufacturer
 you have been authorized for these activities by the machine oper
ating company

The control block covers are secured with sensors. Once you
remove a cover, the EMERGENCY STOP function is triggered.
Thisthen puts the safety functions out of service.

The machine’s EMERGENCY STOP buttons do not work while the

machine is being recovered. For this reason, you must cover all
EMERGENCY STOP buttons for the duration of machine recovery.

For recovery of the machine, call in auxiliary personnel to cordon off

the entire working area and danger zone. If you cannot see the entire
area, you will need signallers for retracting the arm assembly.

BP16_007_1208EN 47
 Specialmodesofoperation

4.4.1 Recovery with on- As long as the machine’s hydraulic drive unit is working, you can
board equipment recover the machine using onboard equipment.

Emergency operation The pump control system is equipped with hydraulic control valves
– pump function which can be operated by hand. They are only for emergency
manual operation of the machine when the control system fails.

BP16_007_1208EN 1

No. 0 Designation
1 Guard

" Cover all EMERGENCY STOP buttons on the machine.

" Remove the guard above the pump control system.

å The machine is in an EMERGENCY STOP state.

48 BP16_007_1208EN
 Specialmodesofoperation

1
2
3
4
5

BP16_007_1208EN 2

No. 0 Designation
1 Accumulator
2 Agitator and water pump control block
3 Transfer tube changeover valve
4 Delivery cylinder emergency control lever
5 Transfer tube damping cock
6 Accumulator dump valve
7 Accumulator pressure gauge

" Press the delivery cylinder emergency control lever to the

leftor right.
å The corresponding delivery cylinder starts to move.

" Once the delivery cylinder has reached its end position,
pressand hold the accumulator dump valve.

" Once the accumulator is filled (see accumulator pressure

gauge), press the transfer tube changeover valve.
å The transfer tube switches over.

" Pump the concrete out of the delivery line, back into the
hopper.

BP16_007_1208EN 49
 Specialmodesofoperation

Emergency operation The arm assembly can be operated manually at the boom control
– boom functions block in the event of a remote control malfunction.

Danger
Machines which offer the OSSfunction do not have a feature to
mechanically safeguard the OSSrange. If the arm assembly is
turned too far with the emergency control levers, the arm assembly
will slew into the prohibited area, and the machine may overturn.
While turning, always keep the arm assembly in the area between
two fully supported support legs.

Arm assemblies with slewing gear transmissions have no mecha

nical stop to limit turning. If the arm assembly is turned too far
withthe emergency control levers, the hydraulic hoses of the arm
assembly will wrap around the slewing head and rip off. When
turning the arm assembly with the emergency control levers,
alwayspay attention to the hydraulic hoses of the arm assembly.

Note
Depending on the mounting position, the emergency control levers
of the boom control block may face upwards or downwards.
Thelever assignment sequence may also be from right to left or
viceversa. It may also be the case that the control block is installed
rotated through 90°. Familiarize yourself with the functions of the
control block by reading the attached notices.

410 BP16_007_1208EN
 Specialmodesofoperation

Example illustration of
aboom control block

1 2 3 4 5 6 7
BP16_007_1208EN 3

No. 0 Designation
1 Preselect lever: support/boom function on − off
2 Slew boom anticlockwise/clockwise
3 Arm1 up − down
4 Arm2 up − down
5 Arm3 up − down
6 Arm4 up − down
7 Arm5 up − down

" Cover all EMERGENCY STOP buttons on the machine.

" Remove the guard above the boom control block.

å The machine is in an EMERGENCY STOP state.

" Press the preselect lever to boom function".

" Fold in the arm assembly by operating the individual

emergency control levers.

BP16_007_1208EN 411
 Specialmodesofoperation

Emergency operation In order to be able to operate the support legs, you must press
– support function thepreselect lever on the boom control block towards to support
function".

Example illustration

BP16_007_1208EN 4

No. 0 Designation
1 Preselect lever: support/boom function on − off
2 Support control block

" Press the preselect lever to support function".

" Fold in each of the support feet and support legs, one after the
other.

412 BP16_007_1208EN
 Specialmodesofoperation

4.4.2 Recovery with an ex- In the event of total failure, you must connect an external hydraulic
ternal hydraulic power power pack in order to be able to recover the machine.
pack
Note
You will need assistance from at least one other person to be able to
recover the machine.

Caution
A maximum output of only 60l/min is permitted for the emergency
hydraulic supply, as the machine’s hydraulic system will otherwise be
overloaded.

Note
After connecting the emergency hydraulic unit, you can
 fold in the arm assembly.
 retract the support legs.

You cannot operate the delivery cylinders in order to pump the con
crete out of the delivery line.

We recommend the following emergency hydraulic unit:

Dynajet R350 mgPlus
This emergency hydraulic unit comes as standard with the necess
ary accessories and is suitable for supplying Putzmeister concrete
pumps in an emergency.

Have a second person help you, as the steps required can be better
carried out with two people.

BP16_009_1210EN 413
 Specialmodesofoperation

Connecting an exter-
1 2 3
nal hydraulic power
pack

6 5 4 BP16_009_1210EN 1

No. 0 Designation
1 Boom control block
2 Shutoff valve
3 Vacuum return flow filter
4 External hydraulic power pack
5 Connector for intake line (yellowmarking)
6 Connection for pressure line (redmarking)

" Lay an intake line and pressure line from the external hydraulic
power pack(4) to the concrete pump.

" Connect the hydraulic power pack intake line to the Connec
tion for intake line (yellowmarking)"(5) on the vacuum return
flow filter(1).

" Open the shutoff valve(2) on the intake side of the vacuum
return flow filter(3).

414 BP16_009_1210EN
 Specialmodesofoperation

" Plug the end of the pressure line into the filler pipe of the hy
draulic fluid reservoir and bleed the hydraulic pack by pump
ing a few litres of hydraulic fluid back into the hydraulic fluid
reservoir under low pressure.

" Place a suitable container underneath the boom control

block(1).

" Open the coupling joint in the line to the boom control block
(redmarking)(6).

" Connect the hydraulic power pack pressure line to the open
Connection for pressure line (redmarking)"(6).
å You can now use the external hydraulic power pack to
pump hydraulic fluid from the concrete pump hydraulic fluid
reservoir into the boom hydraulic circuit.

BP16_009_1210EN 415
 Specialmodesofoperation

Emergency operation The arm assembly can be operated manually at the boom control
– boom functions block in the event of a remote control malfunction.

Danger
Machines which offer the OSSfunction do not have a feature to
mechanically safeguard the OSSrange. If the arm assembly is
turned too far with the emergency control levers, the arm assembly
will slew into the prohibited area, and the machine may overturn.
When turning the arm assembly with the emergency control levers,
always pay attention to the OSSrange.

Arm assemblies with slewing gear transmissions have no mechan

ical stop to limit turning. If the arm assembly is turned too far with the
emergency control levers, the hydraulic hoses of the arm assembly
will wrap around the slewing head and rip off. When turning the arm
assembly with the emergency control levers, always pay attention to
the hydraulic hoses of the arm assembly.

Note
If a machine is fitted with a guard on its boom control block, remov
ing the guard triggers the EMERGENCY STOP function.
You can only operate the boom control block once the guard has
been removed. If no remote control is working, you must control the
arm assembly using the emergency control levers on the boom con
trol block. To do this, push the preselect lever on the boom control
block in the direction of the Boom" symbol.

Depending on the mounting position, the emergency control levers

of the boom control block may face upwards or downwards. The
lever assignment sequence may also be from right to left or vice
versa. It may also be the case that the control block is installed ro
tated through 90°. Familiarise yourself with the functions of the con
trol block by reading the attached notices.

416 BP16_009_1210EN
 Specialmodesofoperation

Example illustration of a
boom control block

1 2 3 4 5 6 7
BP16_009_1210EN 2

No. 0 Designation
1 Preselect lever: support/boom function on−off
2 Slew boom anticlockwise/clockwise
3 Arm1 up−down
4 Arm2 up−down
5 Arm3 up−down
6 Arm4 up−down
7 Arm5 up−down

" Use suitable means to cover all of the EMERGENCY STOP but
tons on the machine.

" Remove the guard above the boom control block.

å The machine is in an EMERGENCY STOP state.

BP16_009_1210EN 417
 Specialmodesofoperation

BP16_009_1210EN 3

" Open the hinged elbow at the back of the hopper, so that the
concrete can flow out of the delivery line.

" Press the preselect lever to boomfunction".

" Move the arm assembly to a steeply rising position.

å The concrete flows back out of the delivery line.

" Fold in the arm assembly by operating the individual emerg

ency control levers.

418 BP16_009_1210EN
 Specialmodesofoperation

Emergency operation In order to be able to operate the support legs, you must press the
– support function preselect lever on the boom control block towards to supportfunc
tion".

Example illustration

BP16_009_1210EN 4

No. 0 Designation
1 Preselect lever: support/boom function on−off
2 Support control block

" Press the preselect lever to supportfunction".

BP16_009_1210EN 419
 Specialmodesofoperation

Example of supporting
the control block

BP16_009_1210EN 5
1 2 3 4 5

No. 0 Designation
1 Preselect lever: support function on−off
2 Raise and lower forward support foot
3 Raise and lower rear support foot
4 Extend and retract forward support leg
5 Swing rear support leg out and in
6 EMERGENCY STOP button

" Fold in each of the support feet and support legs, one after the
other.

Once the arm assembly and support legs have been folded in, you
can remove the machine from the construction site.

420 BP16_009_1210EN
 5 Maintenance

In this section you will find information on maintenance work which is

necessary for the safe and efficient operation of the machine. We
should like here to emphasise expressly that all prescribed checks,
inspections and preventative maintenance work must be conscien
tiously carried out. Otherwise, we will refuse to accept any liability or
to honour the warranty. Should you ever be in any doubt, our After
Sales Department is always ready to give you advice and assist
ance.

BP09_001_9404EN
 Maintenance

5.1 Maintenance intervals The following table shows the intervals for the various maintenance
tasks. The associated maintenance cards can be found further on in
this chapter.

Note
Have the first After Sales service after 100operating hours carried
out by a Putzmeister After Sales Service engineer. The machine
operator responsible for the machine should be present during this
service.

Every ... operating hours

Other
Assembly Action
daily 50 100 250 500 1000 intervals

Lubricate the truck super

weekly
structure

Visual inspection and function

D
check on all safety equipment
General Check the bolted connections
against the tightening torque as required
table

Visual inspection of electrical

D
cabling

Check hydraulic fluid level D

Drain off condensate water D

Visual check of the lines

D
(damage/leaks)

Hydraulic system Full fluid change (after fluid

D
analysis)

Clean fluid sump D

Check hydraulic cylinder

forleak tightness (visual monthly
inspection)

Check the contamination

D
indicator on the filters

Replace the vacuum return flow

Fluid filter D as required
filter element

Replace the suction filter

Together with the vacuum return flow filter element
element

BP09_019_1403EN 51
 Maintenance

Every ... operating hours

Other
Assembly Action
daily 50 100 250 500 1000 intervals

Transfer gearbox full oil change

D annually
(mineral transmission oil)

Transfer gearbox full oil change

D annually
Gearbox (synthetic transmission oil)

Agitator gearbox full oil change D

Slewing gear transmission

D annually
fulloil change

Check the water level D

Water tank
Check the sacrificial anodes annually

according
Check slewing ring bolts to the
retest

Boom pedestal Lubricate the swing bearing

annually
teeth

after
Replace sealing ring
8years

Wear check D

Transfer tube Check and adjust sealing gap D

Check tightening torque of bolts D

Safety locks on couplings D

Delivery line
Check the wall thickness D

Check threaded unions and

D
Delivery piston securing wire

Check wear on delivery pistons weekly

Parts in contact with concrete Wear check D

Centralized lubrication system Check grease level D

52 BP09_019_1403EN
 Maintenance

Every ... operating hours

Other
Assembly Action
daily 50 100 250 500 1000 intervals

Check oil level D

Changing the oil D

Highpressure water pump Cleaning the screen in the
weekly
water filter

Check the bolted connections D

Check oil level D

Changing the oil D

Compressor
Clean air intake filter D

Check the bolted connections D

Inspection D
Cardan shafts (in normal Lubricate the cross pin
operation) bearings (if lubrication nipples D
are present)

Inspection D
Cardan shafts (in extreme Lubricate the cross pin
operating conditions) bearings (if lubrication nipples D
are present)

Truck engine
In accordance with the truck manufacturer’s maintenance information
Truck transmission

Note
For transfer gearboxes that are filled with mineral transmission oil,
the first full oil change must be carried out after 100operating hours.
After this, a full oil change must be carried out after 500operating
hours or at least every year.

For transfer gearboxes that are filled with synthetic transmission oil,
the first full oil change must be carried out after 100operating hours.
After this, a full oil change must be carried out after 1000operating
hours or at least every year.

BP09_019_1403EN 53
 Maintenance

5.2 Residual risks during maintenance, inspection and repair work

5.2.1 Personal protective See the "Safety regulations" chapter for personal protective equip
equipment ment requirements.

Danger
Risk of serious physical injury if personal protective equipment is
notworn. Always wear your personal protective equipment during
maintenance, inspection and repair work. Safety helmet and safety
footwear are a basic requirement. Other personal protective equip
ment is required as listed in the "Safety regulations" chapter.

5.2.2 Personnel Maintenance, inspection and repair work must only be carried out
requirements byqualified personnel. "Qualified personnel" means those who have
completed specialist training for carrying out such work. This training
qualifies them to carry out the activity concerned.

5.2.3 Auxiliary devices Adequate workshop equipment is absolutely necessary for carrying
out maintenance, inspection and repair work.

If you do not have qualified personnel, suitable workshop equipment

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

54 BP09_020_1108EN
 Maintenance

5.2.4 Residual risks During maintenance, inspection and repair work, there are
particularrisks of an accident, because for certain activities,
protective devices must be removed, for example. There follows
alist of residual risks in particular, which may be present during
maintenance, inspection and repair work.

Danger
There is a risk of falling when working above the ground or floor.
Youshould therefore always ensure that you are secure by using
safety harnesses, railings or walkway barriers. Never use machine
parts as climbing aids. Keep all handgrips, steps, railings, platforms
and ladders free from dirt, snow and ice.

Danger
In the area between the mixer drum and frame, there is a risk of
being pulled in, crushed or injured by shearing. Working in this area
is only allowed if the mixer drum is secured with the mixer drum
holder. Read the operating instructions from the truck mixer manu
facturer for information about this.

Danger
Risk of injury through skin contact with functional fluids
(e.g.hydraulic fluid). Avoid contact with functional fluids.
Wear your personal protective equipment. Take note of the safety
data sheets produced by the manufacturer of the functional fluids.

Danger
Risk of burning from hot functional fluids and hot surfaces.
Allow hot functional fluids and hot surfaces to cool first.
Wear your personal protective equipment. Cover hot surfaces
withheatresistant materials.

BP09_020_1108EN 55
 Maintenance

Danger
Risk of injury from pressurised hydraulic fluid. Put the machine out
ofservice before starting maintenance, inspection and repair work.
Depressurise the hydraulic system. Dump pressure from the accu
mulator.

Danger
Risk of injury from compressed air. Put the machine out of service
before starting maintenance, inspection and repair work.
Depressurise the compressed air system.

Danger
Risk of injury from whipping hydraulic hoses. Mechanically pre
stressed hydraulic hoses may lash out when loosening the threaded
union. Wear your personal protective equipment. Secure the
hydraulic hoses tightly in place when loosening the threaded unions.

Danger
Risk of injury from the machine starting unexpectedly. Before starting
maintenance, inspection and repair work, put the machine out of
service and secure it against unexpected restarting (e.g. remove
ignition key and put it in your pocket, place a warning plate on the
controls). If this is not possible, ask someone to stand guard who
can prevent the machine from starting up unexpectedly.

56 BP09_020_1108EN
 Maintenance

5.3 General tightening Tightening torques depend on bolt grade, thread friction and bolt
torques head bearing area. The values given in the following tables are for
guidance. These values should only be used if no other values are
specified in the relevant chapters of the Operating Instructions or in
spare parts sheets.

Caution
You must always use bolts of the same size and property class when
you have to replace bolts. Bolts with adhesive in the locking threads
and self−locking nuts must always be replaced after removal.

5.3.1 Set screws and nuts You will find the maximum tightening torques for set screws and nuts
in spare parts list.

BP09_003_1102EN 57
 Maintenance

5.3.2 Flared screwed joint, After each time the joint is undone, the union nut must be tightened
reassembly again securely without excessive force.

Flared screwed joints

External diam- MA [Nm] External diam- MA [Nm]
eter / Type eter / Type
6 L 20 16 S 130
8 L 40 18 L 120
10 L 45 20 S 250
L 55 25 S 400
12
S 80 30 S 500
15 L 70 38 S 800
* RAD = pipe external diameter
* MA = tightening torque

Note
Hold threaded connection fast against turning with wrench.

10400100

Tightening flared screwed joint

5.3.3 Profiled ring joint, After each time the joint is undone, the union nut must be tightened
reassembly again securely without excessive force to ensure that the joint is
tight.

58 BP09_003_1102EN
 Maintenance

5.4 Functional fluids This section lists all the functional fluids used in your machine.

Caution
Never use hydraulic fluids or lubricants with additives such as
molybdenum. Such additives can attack the bearings.

5.4.1 Hydraulic fluid The hydraulic system is filled with:

− mineral hydraulic fluid (HLP) or
− biologically degradable hydraulic fluid based on a synthetic ester
(HEES) or
− non−readily flammable hydraulic fluid (HFC).

Please see the machine card to find out what the initial filling was in
your machine.

Danger
Never mix hydraulic fluids of different types, i.e. do not mix biologi
cally degradable hydraulic fluids with mineral hydraulic fluids etc.

The hydraulic fluid reservoir has a capacity of 310litres up to the

min" mark and a capacity of 338litres up to the max" mark. The
machine must be standing level, the boom must be folded, and the
supports must be retracted when the hydraulic fluid level is being
checked.

BP09_012_0502EN 59
 Maintenance

Note
Please only use a hydraulic fluid complying with the classification
and requirements standards specified in the lubricant recommenda
tion for topping up or a full fluid change. HEES synthetic esters and
HFC aqueous solutions from different manufacturers must not be
mixed together without prior approval from the manufacturers
concerned.

When hydraulic fluids of different viscosity grades are mixed, the

new viscosity is determined by the mix ratio. Loss of quality is
possible if hydraulic fluids from different manufacturers are mixed.
For this reason, you must always consult the manufacturer before
mixing fluids.

When the hydraulic fluid is changed, some 10−15% of the old hy
draulic fluid remains in the system (in cylinders, pumps, lines, etc).

Take note of VDMA’s changeover guidelines and manufacturer’s

instructions if you are changing over your fluid. Please contact the
manufacturers concerned if you have any queries regarding the
suitability and miscibility of hydraulic fluids.

510 BP09_012_0502EN
 Maintenance

5.4.2 Level of contaminant Level of contaminant 19/16/12 in accordance with ISO4406 is speci
fied for lubrication and the hydraulic system. You can find the level of
contaminant of the initial filling from the test report on the machine
card.

5.4.3 Lubricant analysis We can carry out a lubricant analysis for you should you discover
that the functioning of your machine is impaired with one of the
lubricants or hydraulic fluids used. Please consult Putzmeister,
Department APS (After Sales) and request our analysis kit
(materialno. 257260.004). We will carry out a lubricant analysis
todetermine the cause.

5.4.4 Storage of lubricants Do not store oils and greases in the open air. Water may be
absorbed through the bung hole in the event of changes in the
exposure to the weather.

Only ever store the barrels lying on their side and supported on
timber blocks, with the bung hole facing upwards.

Environmental protection
You must carefully collect all functional fluids, e.g. used oil (including
biologically degradable oils), filters and auxiliary materials and dis
pose of them separately from other waste. You must keep used oils
of various types separate in order to keep disposal costs as low as
possible.

Observe the national and regional regulations applicable to your

area. Only work with waste disposal companies who are approved
by the responsible authorities.

BP09_012_0502EN 511
 Maintenance

5.5 Lubricant You will find suitable lubricants and hydraulic fluids in the tables
recommendation below. Putzmeister accepts no liability for the quality of the lubricants
and hydraulic fluids listed or for changes in quality made by the
lubricant manufacturer without changing the grade designation.

Note
Please use only Putzmeister hydraulic fluid, material no. 239879002,
when you are topping up the hydraulic fluid or carrying out a full fluid
change if your machine was filled with non−readily flammable hy
draulic fluid in the works (HFC as specified in the 7th Luxembourg
Report).

Please use only Putzmeister hydraulic fluid, material no. 239693000,

when you are topping up the hydraulic fluid or carrying out a full fluid
change if your machine was filled with a synthetic ester in the works.

Putzmeister accepts no liability for damages caused by mixing fluids

from different manufacturers.

You must first consult Putzmeister Department APS if you wish to use
hydraulic fluids with viscosity grades other than VG46 (e.g. at higher
ambient temperatures).

The proportion of residual fluid must not be greater than 2% after a

fluid change from HLP to HEES. This means that a flushing filling with
the full quantity of the new hydraulic fluid must be carried out. In
addition, for reasons of gasket compatibility, a fluid change must
becarried out no later than 6months after the machine is commis
sioned. It should also be noted, at this point, that all filters must
bechanged after 50 hours of operation, since deposits may be
dissolved and transported to the filters by the new fluid.

512 BP09_016_0708EN
 Maintenance

Caution
The following points must be complied with in order to prevent
damage:
 You must warm the machine up briefly if you wish to start using it
when the hydraulic fluid temperature is below 0_C. To do this,
engage the power take−off, switch off the concrete pump and
allow the machine to idle for a few minutes.
 The machine should not be placed under full load until the tem
perature of the hydraulic fluid (VG46) has risen above 10_C.
 The ideal temperature for the hydraulic fluid (HLP or HEES, VG46)
is between 40_C and 70_C.

Danger
Never mix hydraulic fluids of different types, i.e. do not mix biologi
cally degradable hydraulic fluids with mineral hydraulic fluids etc.

BP09_016_0708EN 513
 Maintenance

5.5.1 Oils
Agitator Slewing gear Transfer
Rotor gearbox
gearbox transmission gearbox
Requirements
DIN 51 517 DIN 51 517 DIN 51 517
standard
Characteristics synthetic mineral mineral see spare
p parts
p
Viscosity grade, sheet
CLP 220 CLP 220 CLP 220
NLGI Class
Material no. 295246.006 000101.006 000101.006

Note
Truck transmissions, truck engines and independent power units are
filled by the respective manufacturer. Maintenance only in accord
ance with the manufacturer’s specifications.

514 BP09_016_0708EN
 Maintenance

5.5.2 Greases
Greasing Centralized Greasing the pump
(manual) lubrication system tube in rotor pumps
Marking in
accordance K2K−30 K1K−30 
with DIN 51 502
Requirements
DIN 51 825 DIN 51 825 
standard
Characteristics mineral, lithium soap 
Viscosity grade, NLGI Class 2 NLGI Class 1

NLGI Class DIN 51818 DIN 51818
Material no. 360000.009 360001.008 290207.008

Note
We recommend the following grease, rather than those specified in
the lubricant table, should you wish to fill the centralized lubrication
system with a low temperature grease in extremely cold conditions:
Marking in accordance with DIN51502: KE2G−60, NLGI Class2

BP09_016_0708EN 515
516 5.5.3 Hydraulic fluids
Category Mineral oil Synthetic ester Aqueous solutions
Type HLP HEES HFC
Classification
DIN 51502

Maintenance
ISO 6743/0
Requirement
DIN 51524 Part 2  
ISO 6743 Part 4  
VDMA 24318 24568 24317/24320
Others   7th Luxembourg Report
Viscosities
DIN 51519
ISO 3448
2
mm /s ISO VG 32 46 68 46 46
Use 15_C to +80_C 10_C to +90_C 0_C to +95_C 10_C to +80_C 20_C to +60_C
Particular
 biodegrades quickly non−readily flammable
characteristics
Initial filling
Material no. 490984 000171.007 279845.009 484527 239879.002
BECHEM HYDROSTAR FUCHS HYDROTHERM
Manufacturer 
HEES46 46M
Changeover guidelines
VDMA  24569 24314
BP09_017_0905EN
 Maintenance cards

In this section you will find the maintenance cards necessary for this
machine. The table of contents includes a summary of the mainten
ance cards in numerical order, you will find an alphabetical summary
in the Index of key words under the entry for Maintenance cards".

BP09_013_1205EN 517
518
 Maintenancecard
00−001
Page 1 of 2

00–001 Visual checks This maintenance card describes visual checks that you must
carryout before commencing any maintenance work. You will find
the maintenance intervals in the maintenance summary at the start
ofthis chapter.

Note
There are specific risks of an accident associated with maintenance,
inspection and repair work.
For this reason, read the chapter "Safetyregulations" and the
description of the "Residual risks during maintenance, inspection
and repair work" at the start of the chapter entitled "Maintenance"
(i.e. this chapter).

See also the maintenance cards:

Filter change
Hoses

No special tools required.

Danger
Inspect the electrical cables particularly closely and carefully.
Thereis a danger of flash overs from defective cables, particularly
when there is high air or ambient humidity. There is a danger of fire
and explosion through the formation of sparks when the machine is
used in a potentially explosive atmosphere.

WK00_001_1109EN 519
 Maintenancecard
00−001
Page 2 of 2

General The general visual inspections listed below should always be carried
out before any maintenance work, and also each time before starting
work with the machine.

" Check the fill levels of the functional fluids.

" Check that all safety equipment is available and in a fully

functioning condition.

Electrical system Should you locate any damage to the electrical system, you must
have the damage rectified immediately by a qualified electrician.

" Check that all electrical connections are secure and free from
corrosion.

" Check that the electrical cables have no breaks.

" Check the insulation on the electrical cables.

Hydraulic system Timely detection and rectification of damage to the hydraulic system
can prevent lengthy downtimes and high repair costs.

" Check that the displays on the vacuum meter of the suction
filters are still in the green range. The suction filters must be
replaced if the displays are in the red range.
Maintenance card: Filter change

" Check the contamination indicators on the boom filters.

Thefilters are in order if the red button remains depressed.
Thefilter must be replaced if the red button pops out.
Maintenance card: Filter change

" Check the fluid cooler for contamination and deposits.

" Check all hydraulic hose lines for leaks.

Maintenance card: Hoses

" Check all screwed hydraulic screwcouplings for tightness

andleaks.
Maintenance card: Hoses

520 WK00_001_1109EN
 Maintenancecard
01−021
Page 1 of 6

01–021 Transfer gearboxes G64SB This maintenance card describes a full oil change and checking the
and G64SC oil level in the transfer gearbox.

Note
There are specific risks of an accident associated with maintenance,
inspection and repair work. For this reason, read the chapter Safety
regulations" and the description of the Residual risks during main
tenance, inspection and repair work" at the start of the chapter en
titled Maintenance" (i.e. this chapter).

No further maintenance cards required.

No special tools required.

MA The tightening torques can be found in the corresponding

Spareparts list.

WK01_021_1110EN 521
 Maintenancecard
01−021
Page 2 of 6

Caution
The transfer gearbox must never be shifted when under load. Only
shift the transfer gearbox when the Cardan shaft is stationary.

Check that the expirator screws are clean and operating correctly
each time that the oil in the transfer gearbox is changed. If necess
ary, clean or replace the expirator screws.

The transfer gearbox must never be operated if an expirator screw is

missing or defective. Otherwise, leaks may occur due to an increase
in pressure.
This may then cause damage to the transfer gearbox.

Environmental protection
All operating equipment and functional fluids, e.g. oils (including bio
logically degradable oils), filters and auxiliary materials must be
carefully collected and disposed of separately, both from each other
and from other waste. Different categories of oil must also be kept
separately from each other. Nationally and regionally applicable dis
posal regulations must be observed for these materials.

Note
The lubrication circuit on the transfer gearbox lubricates the gearbox
and the connection of the hydraulic pumps.

Check the oil level in the transfer gearbox each time the oil is
changed and top up with gearbox oil, as required.

522 WK01_021_1110EN
 Maintenancecard
01−021
Page 3 of 6

Full fluid change This section describes how to change the transfer gearbox oil.

Note
The full oil change intervals can be found in the maintenance sum
mary at the start of this chapter.

Data concerning oil specification and filling capacity is contained in

the spare parts sheet. It is not permissible to use oils other than
those specified without first consulting with Putzmeister After Sales
department (APS department).

Data concerning parts required and tightening torques can be found

in the spare parts sheet.

Note
Before changing the oil, carry out the following procedures:
 Engage the power takeoff and allow the transfer gearbox to warm
up.
 Disengage the power takeoff.
 Allow the oil to settle for a while, then start the full oil change.

WK01_021_1110EN 523
 Maintenancecard
01−021
Page 4 of 6

The gearbox oil can be added via the bore hole of expirator
screw(1). The oil level in the gearbox must reach as far as oil level
check screw(2).

OIL OIL
1 1

2 2

3
3
WK01_021_1110EN 1

No. 0 Designation
1 Expirator screw
2 Oil level check screw
3 Oil drain plug

" Unscrew expirator screw(1) and oil level check screw(2). In

the process, make sure that no foreign bodies enter the gear
box through the open bore holes.

" Drain the gearbox oil via the bore hole of the oil drain plug(3).

" Clean all screws/plugs that were removed.

" After the oil has drained, replace the sealing ring of the oil
drain plug(3) and screw the plug back into place.

524 WK01_021_1110EN
 Maintenancecard
01−021
Page 5 of 6

" Add the gearbox oil via the bore hole of expirator screw(1).
The oil level must reach as far as the bore hole of oil level
check screw(2).

" After approx. 10minutes, check the oil level and correct, if
necessary.

" Replace the sealing rings of the expirator screw(1) and oil
level check screw(2) and screw the screws back in.

WK01_021_1110EN 525
 Maintenancecard
01−021
Page 6 of 6

526 WK01_021_1110EN
 Maintenancecard
01−028
Page 1 of 4

01–028 Slewing gear transmission This maintenance card describes changing the oil and checking the
oil level in the slewing gear transmission. You will find the mainten
ance intervals in the maintenance summary at the start of this
chapter.

Note
There are specific risks of accidents associated with maintenance,
inspection and repair work. For this reason, read the chapter Safety
regulations" and the description of the Residual risks during main
tenance, inspection and repair work" at the start of the chapter en
titled Maintenance" (i.e.this chapter).

No further maintenance cards required.

No special tools required.

WK01_028_1212EN 527
 Maintenancecard
01−028
Page 2 of 4

Danger
Shut the machine down and dump the accumulator pressure com
pletely before you start working on the slewing gear transmission.

Note
The roller bearing on the transmission drive shaft has permanent
grease lubrication and does not usually need to be lubricated. How
ever, if it becomes necessary to replenish the grease packing as a
result of repairs to the transmission drive shaft, use roller bearing
grease80, DIN51825,
worked penetration220 = 250 (NLGIClass3).

Carry out the full oil change with the machine at operating tempera
ture. This allows the transmission oil to flow out more easily. It is rec
ommended that the transmission be flushed out with a small quantity
of warmed new oil to ensure that wear particles and contamination
are washed out in low ambient temperature conditions.

528 WK01_028_1212EN
 Maintenancecard
01−028
Page 3 of 4

Slewing gear
transmission

WK01_028_1212EN 1

No. 0 Designation
1 Sealing plug
2 Oil filler
3 Inspection glass
4 Oil drain plug

Checking the oil level Check the oil level once a week when the gearbox is idle and the
machine is standing on a level surface. The oil level must not be
lower than the lower edge of the inspection glass or 30mm below
the top of the oil filler opening.

Full fluid change The first full oil change must be carried out after 100operating
hours, every further full oil change must be carried out after 1000op
erating hours, but at least once a year.

WK01_028_1212EN 529
 Maintenancecard
01−028
Page 4 of 4

Fill the gearbox with hydraulic fluid

" Remove the sealing plugs(1) from the oil filler(2).

" Place a suitable container underneath to collect the trans

mission oil which flows out.

" Unscrew the bottom oil drain plug(4) from the gearbox and
allow the transmission oil to drain out.

" Reseal the oil drain opening with the oil drain plug(4).

" Fill the gearbox with transmission oil up to the upper edge of
the inspection glass via the oil filler(3).

" Reseal the oil filler(2) using the sealing plug(1).

530 WK01_028_1212EN
 Maintenancecard
01−020
Seite 1 von 4

01–020 Inspecting, cleaning and lu- This maintenance card describes how to inspect, clean and lubri
bricating the cardan shaft cate the cardan shaft. You will find the maintenance intervals in the
maintenance summary at the start of this chapter.

Note
There are specific risks of an accident associated with maintenance,
inspection and repair work.
For this reason, read the chapter "Safetyregulations" and the
description of the "Residual risks during maintenance, inspection
and repair work" at the start of the chapter entitled "Maintenance"
(i.e. this chapter).

No further maintenance cards required.

No special tools required.

MA The tightening torques can be found in the corresponding

Spareparts list.

Danger
Moving machine components can cause injury and serious material
damage.
The drive must be inoperative when work is carried out on the car
dan shafts. Turn off the engine and make sure that the drive cannot
be put into operation again without permission.

WK01_020_1109EN 531
 Maintenancecard
01−020
Seite 2 von 4

Inspecting the cardan shaft This section describes the inspection of the cardan shaft.

Caution
Repair or replacement of the cardan shaft must only be carried out
by an authorized specialist workshop.

1 2 3

WK01_020_1109EN 1

No. 0 Designation
1 Linear compensation
2 Joint
3 Flange

" Inspect the cardan shaft for changed operating noises, vibra
tions and unusual behaviour. Determine the cause, if necess
ary, and arrange repairs.

" Check whether any noticeable play is present by lifting the

joints (2) and the linear compensation (1). If there is noticeable
play, arrange a repair.

" Check the bolts on the flange (3) for firm seating.

" Inspect the adjacent components for damage.

532 WK01_020_1109EN
 Maintenancecard
01−020
Seite 3 von 4

Cleaning the cardan shaft The cardan shaft should only be cleaned if coarse dirt causes imbal
ances. Cleaning must only be carried out by a specialist workshop.

Caution
Do not use a steam jet or corrosive cleaning agents to clean the car
dan shaft. Otherwise the seals could be damaged by water ingress
and dirt.

Note
After cleaning, the cardan shaft must be lubricated if lubrication
nipples are present.

Lubricating the cardan shaft This section describes the lubrication of the cross pin bearings of the
cardan shaft.

Caution
The maintenance intervals must be adhered to, otherwise
 the cross pin bearings and teeth will become worn and
 the power take−offs can be damaged by the impact of the cardan
shaft.

Also after cleaning or downtime of 6 months or more, the cross pin

bearings of the cardan shaft must be lubricated.

Note
Lubricate the cross pin bearings of the cardan shaft directly at the
lubrication nipples and not at the cross pin bearings.

WK01_020_1109EN 533
 Maintenancecard
01−020
Seite 4 von 4

1 2 3

WK01_020_1109EN 2

No. 0 Designation
1 Grease gun
2 Lubrication nipples
3 Cross pin bearings

" Clean the lubrication nipples (2).

Caution
The grease must not be forced in at too high a pressure or with hard
impacts. The maximum permitted lubrication pressure is 15bar.

" Force just enough grease in at one of the lubrication

nipples(2) at each joint, until the grease escapes visibly from
all four seals on the cross pin bearings (3).

Caution
If grease cannot emerge from all four seals on the cross pin bearings
(3), the cardan shaft must be repaired.

534 WK01_020_1109EN
 Maintenancecard
03−001
Page 1 of 6

03–001 Changing the This maintenance card describes how to carry out a full oil change
hydraulic fluid on the hydraulic system. You will find the service intervals in the
maintenance summary at the start of this section.

Note
There are specific risks of an accident associated with maintenance,
inspection and repair work.
For this reason, read the chapter "Safetyregulations" and the
description of the "Residual risks during maintenance, inspection
and repair work" at the start of the chapter entitled "Maintenance"
(i.e. this chapter).

See also the maintenance cards:

Function checks
Filter change
Hoses

No special tools required.

Note
Cleanliness is of the greatest possible importance in the mainten
ance of hydraulic systems. You must make it impossible for dirt or
other impurities to enter the system. Even small particles may cause
valves to be scored, pumps to seize and choke and control bores to
become blocked.

Hydraulic fluid drums must stand for some time before the fluid is
taken from them. Never roll the barrels to where you will be drawing
off the fluid. Clean bungs, filler caps and their surroundings before
opening them.

If possible, you should use a filler unit to fill up the hydraulic system.
Never leave the tank lid open longer than necessary.

WK03_001_1109EN 535
 Maintenancecard
03−001
Page 2 of 6

Preparation The following tasks must be carried out before starting the full fluid
change:

" Switch off the remote control.

" Switch the hydraulic pumps off.

" Reduce fluid pressure completely.

" Check the contamination indicator on the vent filter of the fluid
reservoir. You must replace the filter element for the vent filter
when the red check ring is visible in the inspection glass.
Maintenance card: Filter change

10401903

1 Red check ring in the inspection glass

536 WK03_001_1109EN
 Maintenancecard
03−001
Page 3 of 6

Danger
The accumulator pressure in pressurized systems must be released.

" Switch the drive engine off.

" Secure the system against unauthorized starting  if you have

any keyed switches, remove the key and disconnect the sup
ply voltage.

" Secure your working area and fix notices to the blocked con
trols and setting devices.

Changing the fluid

10300400

Draining off the fluid

Environmental protection
You must make sure you collect the old hydraulic fluid and dispose
of it in accordance with the regulations. Biologically degradable hy
draulic fluids must also be disposed of separately from other waste,
just like mineral hydraulic fluids!

" Remove a hose from the hydraulic system tank and drain off
the fluid.

WK03_001_1109EN 537
 Maintenancecard
03−001
Page 4 of 6

" Then disconnect all hoses from the tank.

Note
Mark the hoses and their connection points for re−assembly.

10400300

Marking the hoses

" Wipe out all the openings with a lint−free cloth. Wipe as far into
the tank as possible when doing this. You should also re
member that there may also be separate apertures intended
for tank cleaning.

" Remove all filter inserts.

Maintenance card: Filter change

" Change all filters and refit the filter elements.

" Replace any defective hoses.

Maintenance card: Hoses

Environmental protection
Dispose of the old filter inserts in accordance with the regulations in
force.

538 WK03_001_1109EN
 Maintenancecard
03−001
Page 5 of 6

10300500

Filling the tank

" Fill the tank with new fluid.

Note
Only fill the tank through the mesh in the filler inlet. Fill up the tank up
to the Maximum" marking after bleeding and a test run. Use only the
hydraulic fluids specified in the lubrication recommendations.

" Remove the dirt deposits from the oil cooler.

" Check all screwed joints and tighten where necessary. Check
all flared screwed joints.
Maintenance card: Hoses

" Check the electrical connections.

" Carry out all function checks.

Maintenance card: Function checks

" Bleed hydraulic system.

" Carry out several test runs.

" Refit all the safety equipment, markings and notices you have
removed.

WK03_001_1109EN 539
 Maintenancecard
03−001
Page 6 of 6

540 WK03_001_1109EN
 Maintenancecard
03−002
Page 1 of 2

03–002 Function checks This maintenance card describes the inspection of machine func
tions. The inspections are carried out with the machine running. You
will find the service intervals in the maintenance summary at the start
of this chapter.

Note
There are specific risks of an accident associated with maintenance,
inspection and repair work.
For this reason, read the chapter "Safetyregulations" and the
description of the "Residual risks during maintenance, inspection
and repair work" at the start of the chapter entitled "Maintenance"
(i.e. this chapter).

No further maintenance cards required.

The following special tools are required:

Pressure gauge and connections for the tapping points shown in the
hydraulic circuit diagram

Note
Only qualified personnel authorized by us may carry out work on the
hydraulic system. Notify the Putzmeister After Sales department or
the dealer/agent who looks after you immediately should you find
any irregularities.

" Measure the pressures generated by the pumps, using the

measuring equipment specified directly on the pumps, and
compare your results with the values specified in the test
reading.

" Check the proper functioning of the pressure−relief valves in

the high pressure circuit and the pressure accumulator.

WK03_002_1109EN 541
 Maintenancecard
03−002
Page 2 of 2

542 WK03_002_1109EN
 Maintenancecard
04−002
Page 1 of 4

04–002 Hydraulic hoses This maintenance card describes how to check and replace the
hydraulic hoses. You will find the maintenance intervals in the main
tenance summary at the start of this chapter.

Note
There are specific risks of an accident associated with maintenance,
inspection and repair work.
For this reason, read the chapter "Safetyregulations" and the
description of the "Residual risks during maintenance, inspection
and repair work" at the start of the chapter entitled "Maintenance"
(i.e. this chapter).

No further maintenance cards required.

No special tools required.

MA The tightening torques can be found in the corresponding

Spareparts list.

Note
Check all hydraulic hoses (including hose fittings) with the machine
running.
You must replace the hydraulic hoses at the slightest sign of damage
or even mere indications of threatened damage.

WK04_002_1110EN 543
 Maintenancecard
04−002
Page 2 of 4

Environmental protection
All functional fluids and operating materials, e.g. oils (including bio
logically degradable oils), filters and auxiliary materials must be
carefully collected and disposed of separately, both from each other
and from other waste. Different categories of oil must also be kept
separately from each other. Nationally and regionally applicable dis
posal regulations must be observed for these materials.

Leaking
hydraulic hoses

10400800

Check hydraulic hoses

Dark and moist patches on the fitting are external signs of incipient
damage. Check:
− the hydraulic hoses for kinks, cracks or a porous surface and
− whether the hydraulic hoses have been laid without restrictions.

Note
Beware of strong sunlight, the action of heat and the effects of
chemicals.

544 WK04_002_1110EN
 Maintenancecard
04−002
Page 3 of 4

Replacing The procedure for replacing hydraulic hoses is as follows:

hydraulic hoses
" Shut down the machine and secure against unauthorized
starting.

" Fully dump any (residual) pressure in the hydraulic system.

Danger
Hydraulic hoses may be mechanically pre−stressed. There is a risk
of injury from whipping hoses.

" Take care when undoing the joints.

" Close the connection points with a plug immediately you have
removed the old hydraulic hoses. No dirt may enter the hy
draulic circuit and the hydraulic circuit must not run empty.

Danger
Hydraulic hoses should not be more than six years old, including a
storage time of two years. Take note of the date of manufacture on
the hydraulic hoses.

" Keep the hydraulic hoses free from dirt.

" Fit the hydraulic hoses to be free from bends or points of ab
rasion.

" Bleed the hydraulic system.

" Carry out a test run and inspect all hydraulic hoses again after
fitting new hydraulic hoses.

WK04_002_1110EN 545
 Maintenancecard
04−002
Page 4 of 4

Flared screwed joints

10400100

Tightening flared screwed joint

" Check whether the flared screwed joints are tight.

Note
You may only tighten leaking flared screwed joints with the permitted
tightening torque. Tighten the flared screwed joints until you clearly
feel an increase in the force required if you do not have a torque
wrench available. You must replace these flared screwed joints if
leaking continues.

The tightening torques can be found in the table Flared screwed

joints" at the start of this chapter.

546 WK04_002_1110EN
 Maintenancecard
04−014
Page 1 of 4

04–014 Changing the ventilation This maintenance card describes how to change the ventilation filter
filter element element.

Note
There are specific risks of an accident associated with maintenance,
inspection and repair work.
For this reason, read the chapter "Safetyregulations" and the
description of the "Residual risks during maintenance, inspection
and repair work" at the start of the chapter entitled "Maintenance"
(i.e. this chapter).

No further maintenance cards required.

No special tools required.

Maintenance
Ventilation filter for ... Filter element
indicator
water tank no no
fuel tank yes no
hydraulic fluid reservoir yes yes

Note
When a maintenance indicator is integrated into the screw cap on
the filter housing, you can use it to detect the latest time that the filter
element should be changed. Without a maintenance indicator,
change the filter elements when they appear very dirty.

WK04_014_1109EN 547
 Maintenancecard
04−014
Page 2 of 4

8
1
7
6

2 3 4 5

WK04_014_1109EN 1

No. 0 Designation
1 Filter element
2 3−stage maintenance indicator
3 Rotary knob, resets the maintenance indicator
4 Screw cap with maintenance indicator
5 Hydraulic fluid reservoir filter housing
6 Fuel/water tank filter housing
7 Screw cap without maintenance indicator
8 Filter element (optional)

548 WK04_014_1109EN
 Maintenancecard
04−014
Page 3 of 4

" Undo the screw cap from the filter housing.

" Remove the filter element from the filter housing.

Environmental protection
Dispose of used filter elements in accordance with the relevant
regulations.

Caution
The filtering process causes dirt particles to accumulate in the filter
housing. You must therefore clean the filter housing thoroughly
before refitting the new filter element, as otherwise the new filter
element will rapidly become clogged again.

" Clean the filter housing and the inside of the screw cap with a
clean cloth.

" When fitted, reset the 3−stage maintenance indicator by turn

ing the rotary knob anti−clockwise in the direction of the arrow.
å The 3−stage maintenance indicator jumps back to its orig
inal position.

" Insert a new filter element into the screw cap.

" Screw the screw cap with filter element inserted back onto the
filter housing.

WK04_014_1109EN 549
 Maintenancecard
04−014
Page 4 of 4

550 WK04_014_1109EN
 Maintenancecard
04−018
Page 1 of 10

04–018 Hydraulic fluid filter change This maintenance card describes how to change the elements for
the vacuum filter and the vacuum return flow filter. You will find the
maintenance intervals in the maintenance summary at the start of
this chapter.

Note
There are specific risks of an accident associated with maintenance,
inspection and repair work. For this reason, read the chapter "Safety
regulations" and the description of the "Residual risks during main
tenance, inspection and repair work" at the start of the chapter en
titled "Maintenance" (i.e. this chapter).

No further maintenance cards required.

No special tools required.

Note
Cleanliness is of the utmost importance in the maintenance of hy
draulic systems. Prevent any type of dirt and contamination from
entering the system. Even small particles of dirt may cause valves to
be scored, pumps to seize and throttle and control bores to become
blocked.

Hydraulic fluid barrels must stand for some time before the fluid is
removed from them. Do not roll the barrels to the tapping point.
Clean bungs and filler lids as well as the area around them before
opening.

If possible, you should use a charging set to fill up the hydraulic sys
tem. Never leave the tank lid open longer than necessary.

WK04_018_1111EN 551
 Maintenancecard
04−018
Page 2 of 10

Caution
Filter elements freely available on the market have too low a flow
rate. You must, therefore, only ever use original Putzmeister filter el
ements in order to prevent damage to the machine.

You must never attempt to clean filter elements. These must always
be replaced.

Environmental protection
All functional fluids and operating materials, e.g. oils (including bio
logically degradable oils), filters and auxiliary materials must be
carefully collected and disposed of separately, both from each other
and from other waste. Different categories of oil must also be kept
separately from each other. Nationally and regionally applicable dis
posal regulations must be observed for these materials.

Preparation The following tasks must be carried out before changing the filter:

" Switch off the hydraulic pumps.

" Switch off the engine/motor.

" Dump the fluid pressure completely.

" Switch off the remote control.

Danger
Escaping pressurized hydraulic fluid can cause serious or fatal in
juries. Relieve the pressure in the hydraulic system and the accumu
lator.

" Secure the machine against being started by unauthorized

persons − if you have any keyoperated switches, remove the
key and disconnect the supply voltage.

" Secure your working area and fix information plates to the
locked controls and setting devices.

552 WK04_018_1111EN
 Maintenancecard
04−018
Page 3 of 10

Removing the vacuum

filter
Caution
The vacuum filter and vacuum return flow filter are interconnected by
a lead with a check valve. Hydraulic fluid from the vacuum filter can
escape via the vacuum return flow filter. When changing the filter el
ement, proceed in the specified sequence:
 Remove the vacuum filter element.
 Replace the vacuum return flow filter element.
 Change the vacuum filter element.
 Bleed the vacuum return flow filter.

5
WK04_018_1111EN 1

No. 0 Designation
1 Lid
2 Hexagon nut
3 Plug
4 Filter element
5 Magnetic rod

WK04_018_1111EN 553
 Maintenancecard
04−018
Page 4 of 10

" Place a container under the filter casing to allow you to catch
the escaping hydraulic fluid.

" Unscrew the hexagon nuts as far as the stop and remove the
filter element without turning it to the stop.
å A shutoff valve automatically interrupts the hydraulic fluid
supply.

" Open the upper stopper to provide an air supply.

" Turn the cover anticlockwise and remove it.

" Leave the hydraulic fluid to run out of the filter casing.

" Pull out the filter element.

Note
Observe the sequence and proceed to change the vacuum return
flow filter.

554 WK04_018_1111EN
 Maintenancecard
04−018
Page 5 of 10

Changing the vacuum

return flow filter
1

WK04_018_1111EN 2

No. 0 Designation
1 Air supply plug
2 Lid
3 Drain plug

" Place a container with a minimum capacity of 10l under the

drain plug on the cover to allow you to catch the escaping hy
draulic fluid.

" Open the upper stopper to provide an air supply.

" Open the drain plug and allow the hydraulic fluid to run out of
the filter casing.

WK04_018_1111EN 555
 Maintenancecard
04−018
Page 6 of 10

WK04_018_1111EN 3

No. 0 Designation
1 Lid
2 Separation plate
3 Filter element

" Unscrew the cover.

" Pull the separation plate out, by turning it slightly anticlock

wise.
å More hydraulic fluid will escape.

" Pull the filter element out, by turning it slightly anticlockwise.

556 WK04_018_1111EN
 Maintenancecard
04−018
Page 7 of 10

" Examine all components for mechanical damage, paying par

ticular attention to the sealing surfaces, thread and Orings.

" Replace any damaged components, if necessary.

" Lubricate the sealing surfaces, thread and Orings with clean
hydraulic fluid.

Caution
The filtering process causes dirt and contamination particles to
accumulate in the filter housing. You must therefore clean the filter
housing thoroughly before refitting the new filter element, as other
wise the new filter element will rapidly become clogged again.

" Clean the filter housing thoroughly with a clean rag.

" Fit a new filter element, by turning it slightly clockwise.

" Fit the separation plate on the filter element, by turning it

slightly clockwise.

WK04_018_1111EN 4

" Screw in the cover.

" Screw in the drain plug.

WK04_018_1111EN 557
 Maintenancecard
04−018
Page 8 of 10

Fitting the vacuum

filter
" Wipe the magnetic rod lengthways with a clean rag.

" Examine all components for mechanical damage, paying par

ticular attention to the sealing surfaces, thread and Orings.

" Replace any damaged components, if necessary.

" Lubricate the sealing surfaces, thread and Orings with clean
hydraulic fluid.

Caution
The filtering process causes dirt and contamination particles to
accumulate in the filter housing. You must therefore clean the filter
housing thoroughly before refitting the new filter element, as other
wise the new filter element will rapidly become clogged again.

" Clean the filter housing thoroughly with a clean rag.

" Fit a new filter element on the magnetic rod.

" Place the cover on the casing, turn it clockwise and refit it fully.

" Securely screw in the cover.

558 WK04_018_1111EN
 Maintenancecard
04−018
Page 9 of 10

Bleeding the vacuum

return flow filter

WK04_018_1111EN 5

" Open a plug on both the suction side and the return side of the
filter casing.

" Fill up with new hydraulic fluid via the openings until the filter
casing is full.

" Screw the plugs back in.

WK04_018_1111EN 559
 Maintenancecard
04−018
Page 10 of 10

560 WK04_018_1111EN

06–047 Delivery piston replacement
on the dual piston end–of–
travel positioning system
WK06_047_1109EN
Maintenancecard
06−047
Page 1 of 10
This maintenance card describes how to replace the delivery pistons
on a 2−KEP system. In the 2−KEP (piston end−of−travel positioning)
system, there is a ball valve fitted in the stroke correction line of each
drive cylinder. You will find the maintenance intervals in the mainten
ance summary at the start of this chapter.
Note
There are specific risks of an accident associated with maintenance,
inspection and repair work. For this reason, read the chapter "Safety
regulations" and the description of the "Residual risks during main
tenance, inspection and repair work" at the start of the chapter en
titled "Maintenance" (i.e. this chapter).
No further maintenance cards required.
No special tools required.
Note
Damage to the delivery pistons must be rectified without delay.
Putzmeister accepts no warranty claims for damage to the machine
resulting from failure to properly observe the maintenance regula
tions.
Danger
Secure the working area. Place warning notices on blocked control
and setting devices.
561
 Maintenancecard
06−047
Page 2 of 10

You will have to start up and shut down the machine a number of
times when replacing the delivery pistons. The operations necessary
for this task are described below and must be carried out conscien
tiously. Execute all machine functions from the cable remote control.

Shutting down the Proceed as follows to shut down the machine:

machine
" Switch off the engine.

" Press the EMERGENCY STOP button.

" Dump the pressures completely.

Danger
Dump the accumulator pressure completely in systems with pressure
accumulators.

Starting up the Proceed as follows to start up the machine:

machine
" Unlock the EMERGENCY STOP button and sound the horn.

" Switch the engine on.

Caution
Do not switch the pump on until you are called upon to do so.

562 WK06_047_1109EN
 Maintenancecard
06−047
Page 3 of 10

Blocking the drive cyl- You must block each associated drive cylinder in the end position
inders in the end posi- before you are able to remove the delivery pistons.
tion
Note
To lock the drive cylinders in the end position with minimum wear",
set the pumping rate below 50% and the engine speed to approxi
matelyhalf the maximum value.

Closing the stroke Each drive cylinder stroke correction line has a ball valve (KEP) that
correction lines is fitted open (markings parallel to the line) ex works and is locked
against turning. It is necessary to close the stroke correction line to
the drive cylinder from which you are removing the delivery piston
using the ball valve.

20202301

The works fits the ball valve (KEP) in the open state

WK06_047_1109EN 563
 Maintenancecard
06−047
Page 4 of 10

20202302

1 As−fitted position secured against rotation

2 Rotate position

" Undo the bolt on the handle and remove the handle.

" Lift up the guide washer and refit it rotated through 90_ .

564 WK06_047_1109EN
 Maintenancecard
06−047
Page 5 of 10

WK06_047_1109EN 1

Ball valve (KEP) when closed

" Replace the handle.

" Press the Change−over" switch when the concrete pump is

running and hold it down until the concrete pump switches off.

" Close the ball valve once the two drive cylinders have stopped
moving.

Note
Just after you have closed the ball valve, there is a possibility that
one of the drive cylinders may move again briefly until both drive cyl
inders are finally in mechanical end position.

" Now switch the concrete pump off.

" Then you can release the Change−over" switch.

WK06_047_1109EN 565
 Maintenancecard
06−047
Page 6 of 10

Piston replacement When replacing pistons you may work with the remote control on the
platform.

1 2 3 2 4

5
10600301

1 Piston rod flange

2 Fastening bolts
3 Securing wire
4 Delivery piston
5 Spacer flange

" Shut the machine down.

" Drain the water from the water box and remove the cover.

" Start the machine up.

" Move the drive piston of the delivery piston to be removed to

its end position. The spacer flange must be fully visible in the
water box.

" Shut the machine down.

" Remove the securing wire from the fastening bolts.

566 WK06_047_1109EN
 Maintenancecard
06−047
Page 7 of 10

10600701

1 Fastening bolts

" Unscrew the fastening bolts for the spacer flange from the
drive piston rod and from the delivery piston and remove the
spacer flange.

" Start the machine up.

" Slowly bring the drive piston rod up to the delivery piston.

" Shut the machine down.

WK06_047_1109EN 567
 Maintenancecard
06−047
Page 8 of 10

1
10600800

1 Pulling bolts

" Remove the protective caps from the two pulling bolts and bolt
the delivery piston to the drive piston using the two pulling
bolts.

" Start the machine up.

" Pull the delivery piston completely out of the delivery cylinder.

" Shut the machine down.

" Undo the threaded joint and remove the old delivery piston.

" Thoroughly clean the delivery piston edge at the end of the
water box.

Caution
Do not use any hard objects or caustic cleaning agents to clean the
delivery cylinder. These might damage the chrome coating.

568 WK06_047_1109EN
 Maintenancecard
06−047
Page 9 of 10

" Grease a new delivery piston heavily with acid−free grease

(e.g. Vaseline).

" Bolt the new delivery piston to the drive cylinder using the two
pulling bolts.

" Start the machine up.

" Slowly advance the drive piston rod and push the new delivery
piston carefully into the delivery cylinder. The pulling bolts must
remain freely accessible.

" Shut the machine down.

" Unscrew the pulling bolts and replace the protective caps.

" Start the machine up.

" Retract the drive piston rod sufficiently for the spacer flange to
fit between the delivery piston and the drive piston.

" Shut the machine down.

" Insert the spacer flange and fasten all the bolts.

" Tighten the bolts to the specified tightening torques and se
cure them with a stainless steel wire.

WK06_047_1109EN 569
 Maintenancecard
06−047
Page 10 of 10

Opening the stroke

correction lines

20202301

Open the ball valve (KEP) and secure it against rotation

" Open the ball valve (KEP) when delivery piston replacement is
completed.

" Replace the guide washer so that it is blocked in position, fit

the handle and bolt it down.

Caution
The ball valves must be opened and secured by the guide washers
when the machine is being operated.

The pump may not be able to change the stroke over any longer if
the ball valve is closed.

" Then carry out a test run.

Note
Replace the second delivery piston in the same way.

570 WK06_047_1109EN
 Maintenancecard
07−001
Page 1 of 2

07–001 Lubricating the This maintenance card describes the lubrication of all lubrication
S transfer tube points on the transfer tube if you do not have a centralized lubrica
tion system. You will find the maintenance intervals in the mainten
ance summary at the start of this chapter.

Note
There are specific risks of an accident associated with maintenance,
inspection and repair work. For this reason, read the chapter "Safety
regulations" and the description of the "Residual risks during main
tenance, inspection and repair work" at the start of the chapter en
titled "Maintenance" (i.e. this chapter).

No further maintenance cards required.

The following special tools are required:

Grease gun

Note
Use a grease with the marking K2K in accordance with DIN51502,
NLGI Class2.

WK07_001_1109EN 571
 Maintenancecard
07−001
Page 2 of 2

Lubrication intervals You should grease the lubrication points one to three times daily, un
less a different interval is specified. You should apply the grease until
you can see it emerging.

30300103

Transfer tube and plunger cylinder lubrication diagram

572 WK07_001_1109EN
 Maintenancecard
07−068
Page 1 of 8

07–068 Replacing the transfer tube This maintenance card describes how to replace the transfer tube
bearing bearing. You will find the maintenance intervals in the maintenance
summary at the start of this chapter.

Note
There are specific risks of an accident associated with maintenance,
inspection and repair work. For this reason, read the chapter "Safety
regulations" and the description of the "Residual risks during main
tenance, inspection and repair work" at the start of the chapter en
titled "Maintenance" (i.e. this chapter).

No further maintenance cards required.

No special tools required.

MA The tightening torques can be found in the corresponding

Spareparts list.

Danger of crushing
A pressurized hydraulic system may cause the machine to move
suddenly, which may result in you being seriously injured if you are
working on the machine. To avoid risk, shut the machine down and
secure it against unauthorized or accidental starting.

Caution
Use only suitable lifting equipment for lifting components.

WK07_068_1109EN 573
 Maintenancecard
07−068
Page 2 of 8

Note
Wear parts must be replaced in the event of one of the following:
 Severe wear is visible
 Concrete is seeping out

When maintenance work is carried out, the machine must have been
shut down. The operations necessary for this task are described
below and must be carried out conscientiously. Use the remote con
trol here.

Shutting down the Shut down the machine as follows:

machine
" Switch off the engine.

" Dump the pressures completely.

Danger
Dump the accumulator pressure completely in systems with pressure
accumulators.

Starting up the The machine may be started up differently depending on the ma
machine chine model. When you are starting up a truck−mounted concrete
pump, proceed as follows:

" Unlock the EMERGENCY STOP button and sound the horn.

" Switch the engine on.

Caution
Do not switch the pump on until you are called upon to do so.

574 WK07_068_1109EN
 Maintenancecard
07−068
Page 3 of 8

Removing the transfer The S transfer tube is mounted in the transfer tube bearing in the
tube bearing rear wall of the hopper.

" Shut the machine down.

" Open the grille on the hopper and secure the grille.

" Attach suitable lifting gear to the S transfer tube.

" Remove the lubrication lines from the transfer tube bearing.

1 2

3 4 5 6 1 7
WK07_068_1109EN 1

No. 0 Designation
1 Fastening bolts
2 Transfer tube bearing
3 Wedge
4 Spring pin
5 Retaining bolt for hinged elbow
6 Pulling bores with jacking thread
7 Hinged elbow

Danger
The hinged elbow(7) folds open immediately when the wedge(3) is
removed from the retaining bolt(5). This presents a risk of injury.
Hold the hinged elbow(7) securely in position when removing the
wedge(3).

WK07_068_1109EN 575
 Maintenancecard
07−068
Page 4 of 8

" Release the wedge(3) by removing the spring pins (4).

" Remove the wedge(3) from the retaning bolt(5).

" Open the hinged elbow(7).

" Unscrew the two fastening bolts(1) on the transfer tube bear
ing(2).

" Insert the two supplied pulling bolts into the pulling bores(6).
å The transfer tube bearing(2) is forced out.

" Inspect the gasket set on the transfer tube bearing(2) for wear
and replace the gasket set if necessary.

576 WK07_068_1109EN
 Maintenancecard
07−068
Page 5 of 8

Replacing the transfer

tube bearing gasket
set

WK07_068_1109EN 2

Bending the grooved ring to make installation easier

Caution
The mounting position for the gasket set in the transfer tube bearing
can be found in the corresponding spare parts sheet.

" Grease the new gasket set.

" Bend the grooved ring to make installation easier.

" Insert the gasket set as shown on the spare parts sheet.

Note
Clean the transfer tube bearing before refitting and grease the seals.
Check the lubricant bores, in particular, for proper functioning. This
is done by connecting the lubrication lines and forcing grease
through the openings.

WK07_068_1109EN 577
 Maintenancecard
07−068
Page 6 of 8

Fitting the transfer

tube bearing 1 2

3 4 5 1 6
WK07_068_1109EN 3

No. 0 Designation
1 Fastening bolts
2 Transfer tube bearing
3 Wedge
4 Retaining bolt for hinged elbow
5 Pulling bores with jacking thread
6 Hinged elbow

Note
Note the position of the lubrication openings when installing the
transfer tube bearing(2).

" Place the transfer tube bearing(2) onto the S transfer tube
outlet and screw securely in position.

578 WK07_068_1109EN
 Maintenancecard
07−068
Page 7 of 8

Close hinged elbow The hinged elbow must be closed as follows:

2 2 3

5 4

WK07_068_1109EN 4

No. 0 Designation
1 Inscription "0" or recess
2 Retaining bolt for hinged elbow
3 Hinged elbow
4 Wedge
5 Tie bolt for retaining bolt(2)
6 Spring pin

WK07_068_1109EN 579
 Maintenancecard
07−068
Page 8 of 8

Note
The retaining bolt(2) must be screwed to the tie bolt(5) as shown in
the above illustration (inscription "0" or recess (1) facing upwards).
Only then can the wedge(4) for closing the hinged elbow be fitted.

" Check that the retaining bolt(2) is seated securely.

" Check the mounting position of the retaining bolt(2).

" Close the hinged elbow (3) with the wedge (4).

" Secure the wedge (4) using the spring pin (6).

580 WK07_068_1109EN
 Maintenancecard
07−070
Page 1 of 16

07–070 Replacing the switching This maintenance card describes how to replace the switching shaft
shaft bearing (flanged bearing (flanged bearing). You will find the maintenance intervals in
bearing) the maintenance summary at the start of this chapter.

Note
There are specific risks of an accident associated with maintenance,
inspection and repair work. For this reason, read the chapter "Safety
regulations" and the description of the "Residual risks during main
tenance, inspection and repair work" at the start of the chapter en
titled "Maintenance" (i.e. this chapter).

See also the maintenance cards:

Adjusting the S transfer tube

No special tools required.

MA The tightening torques can be found in the corresponding

Spareparts list.

Danger of crushing
A pressurized hydraulic system may cause the machine to move
suddenly, which may result in you being seriously injured if you are
working on the machine. To avoid risk, shut the machine down and
secure it against unauthorized or accidental starting.

Caution
Use only suitable lifting equipment for lifting components.

WK07_070_1109EN 581
 Maintenancecard
07−070
Page 2 of 16

Note
Wear parts must be replaced in the event of one of the following:
 Severe wear is visible
 Concrete is seeping out

When maintenance work is carried out, the machine must have been
shut down. The operations necessary for this task are described
below and must be carried out conscientiously. Perform all machine
functions using the remote control.

Shutting down the Proceed as follows to shut down the machine:

machine
" Switch off the engine.

" Dump the pressures completely.

Danger
Dump the accumulator pressure completely in systems with pressure
accumulators.

582 WK07_070_1109EN
 Maintenancecard
07−070
Page 3 of 16

Starting up the The machine may be started up differently depending on the ma
machine chine model. When you are starting up a truck−mounted concrete
pump, proceed as follows:

" Unlock the EMERGENCY STOP button and sound the horn.

" Switch the engine on.

Caution
Do not switch the pump on until you are called upon to do so.

When you are starting up a stationary concrete pump, proceed as

follows:

" If there is a throttle, set it to one third.

" Start up the engine.

" Select a low output.

" Switch the pump on.

WK07_070_1109EN 583
 Maintenancecard
07−070
Page 4 of 16

Overview
1 2 3 4 5 6 7 8 9 10 11

14 13 12
WK07_070_1109EN 1

No. 0 Designation
1 Pulling bore for ball cup
2 Ball cup
3 Hydraulic port
4 Plunger cylinder
5 Retaining plate
6 Retaining plate fastening bolts
7 Switch lever
8 Clamping bolts with nuts
9 Disc
10 Switching shaft
11 Hexagon nut
12 Flanged bearing
13 Pulling bore for flanged bearing (two diagonally opposite
each other)
14 Fastening bolt for flanged bearing (covered)

584 WK07_070_1109EN
 Maintenancecard
07−070
Page 5 of 16

Removing the switch- The switching shaft (10) of the S transfer tube is supported in the
ing shaft bearing flanged bearing (12) in the front wall of the hopper.
(flanged bearing)

" Shut the machine down.

" Remove any lubrication lines from the retaining plate(5) and
flanged bearing(12).

WK07_070_1109EN 2

Unbolting the retaining plate

" Screw the fastening bolts(6) out of the retaining plate(5) and
remove the retaining plate(5). (You will have to replace the
lock washers on the fastening bolts (6) with new ones on reas
sembly.)

WK07_070_1109EN 585
 Maintenancecard
07−070
Page 6 of 16

Environmental protection
All functional fluids and operating materials, e.g. oils (including bio
logically degradable oils), filters and auxiliary materials must be
carefully collected and disposed of separately, both from each other
and from other waste. Different categories of oil must also be kept
separately from each other. Nationally and regionally applicable dis
posal regulations must be observed for these materials.

" Place an oil sump pan under the working area.

" Place a container under the bulkhead union as well.

" Unscrew the hydraulic hose that leads to the plunger cylinder
from the bulkhead union.

" Catch the hydraulic fluid flowing out of the hydraulic line and
hydraulic hose.

" Seal the hydraulic line with a plug.

586 WK07_070_1109EN
 Maintenancecard
07−070
Page 7 of 16

1 2 3 4

WK07_070_1109EN 3

No. 0 Designation
1 Plunger cylinder
2 Locking plate
3 Ball cup
4 Pulling bore

Note
You can press a plunger cylinder(1) out of the ball cup(3) from the
piston side as shown. If the ball cup is worn, you can screw a bolt
into the pulling bore(4) for the ball cup and press out the plunger
cylinder with the ball cup.

" Remove the locking plate(2).

" Press the piston rod on the plunger cylinder(1) back.

" Catch the hydraulic fluid flowing out of the hydraulic hose.

" Remove the plunger cylinder(1) and hydraulic hose.

WK07_070_1109EN 587
 Maintenancecard
07−070
Page 8 of 16

" If required, remove the hydraulic hose from the plunger cylin
der(1).

" Remove the second plunger cylinder(1) in the same way.

" Unscrew the hexagon nut and remove it from the switching
shaft, and remove the washer.

Note
If the switch lever has a slot, this means that the switch lever is fitted
with clamping bolts, and a pulling bolt is also provided.

1 2 3

4 5 6
WK07_070_1109EN 4

No. 0 Designation
1 Clamping bolts
2 Switch lever
3 Slot
4 Pulling bolt
5 Holes for clamping bolts
6 Nuts for clamping bolts

588 WK07_070_1109EN
 Maintenancecard
07−070
Page 9 of 16

WK07_070_1109EN 5

Unscrew and remove the clamping bolts if the switch lever is

slotted

" If available, unscrew and remove the clamping bolts(1) from

the switch lever (2).

Note
One of the holes (5) for the clamping bolts(1) is also the pulling bore
for the switch lever(2).

" If required, force the switch lever(2) apart by turning the pul
ling bolt supplied(4) into the pulling bore.

" Pull the switch lever(2) from the switching shaft.

WK07_070_1109EN 589
 Maintenancecard
07−070
Page 10 of 16

1 2

WK07_070_1109EN 6

No. 0 Designation
1 Fastening bolt
2 Pulling bores (two, diagonally opposite each other)
3 Flanged bearing

" Unscrew the fastening bolt(1) from the flanged bearing (3).

" Attach suitable lifting gear to the S transfer tube.

" Press out the flanged bearing(3) by turning the two pulling
bolts supplied into the pulling bores(2).

" Check the gasket set on the flanged bearing for wear, and re
place the gasket set if required.

590 WK07_070_1109EN
 Maintenancecard
07−070
Page 11 of 16

Replacing the gasket

set in the flanged
bearing

WK07_070_1109EN 7

Removing the retaining ring

" Remove the retaining ring.

WK07_070_1109EN 8

Removing the old grooved ring

" Remove the old gasket set. To do this, you may have to cut
open the rings.

WK07_070_1109EN 591
 Maintenancecard
07−070
Page 12 of 16

WK07_070_1109EN 9

Inserting the new grooved ring

" Clean the flanged bearing.

" Grease the new gasket set.

Caution
For the mounting position of the grooved ring in the flanged bearing,
please refer to the accompanying spare parts sheet.

" Insert the gasket set.

" If there is a friction bearing bush, check it and replace if

necessary.

" Fit the retaining ring.

592 WK07_070_1109EN
 Maintenancecard
07−070
Page 13 of 16

Wear sleeve on
flanged bearing and
collared washer

1 2 3 4 5
WK07_070_1109EN 10

No. 0 Designation
1 Wear sleeve on the flanged bearing
2 Flanged bearing
3 Collared washer
4 Bore
5 Tab

" Bend the tab (5) on the collared washer(3) downwards.

" Place the collared washer(3) on the flanged bearing (2) so that
the tab (5) is located in the bore (4), thereby securing the
washer against rotation.

" Insert the wear sleeve(1) into the flanged bearing (2).

Note
Note the location of the lubrication bores when fitting the flanged
bearing (2).

" Grease the inside of the wear sleeve (1) with Anti−Seize AS
450 Assembly Paste" or an equivalent assembly grease.

" Locate the complete flanged bearing(2) on the switching shaft

and bolt the flanged bearing (2) in place.

WK07_070_1109EN 593
 Maintenancecard
07−070
Page 14 of 16

Mounting the switch

1 2 3 4 5
lever

7 6
WK07_070_1109EN 11

No. 0 Designation
1 Switch lever
2 Switching shaft
3 Switching shaft bearing (flanged bearing)
4 Groove
5 Wear sleeve
6 Flattened tooth
7 Notch

" Grease the teeth on the switch lever (1) and the switching shaft
(2) with Anti−Seize AS 450 assembly paste" or equivalent as
sembly grease.

" Fit the switch lever(1) so that the flattened tooth(6) on the
switching shaft(2) sits in the notch (7) on the switch lever(1).

" Fit the switch lever(1) on the switching shaft(2), so that the
switch lever(1) sits in the groove (4) on the wear sleeve(5).

594 WK07_070_1109EN
 Maintenancecard
07−070
Page 15 of 16

" Fit the washer to the switching shaft and screw the hexagon
nut onto the switching shaft.

" Lubricate the flanged bearing using the centralized lubrication

system / grease gun.

" Insert the plunger cylinder.

Note
The hydraulic system must be bled once assembly is complete if you
have removed the hydraulic hoses from the plunger cylinders. Do
this by starting up the pump slowly and switching the Stransfer tube
across slowly a few times.

" Adjust the S transfer tube so that it switches correctly.

Maintenance card: Adjusting the S transfer tube

WK07_070_1109EN 595
 Maintenancecard
07−070
Page 16 of 16

596 WK07_070_1109EN
 Maintenancecard
07−071
Page 1 of 14

07–071 Replace the spectacle wear This maintenance card describes how to replace the spectacle wear
plate plate. You will find the maintenance intervals in the maintenance
summary at the start of this chapter.

Note
There are specific risks of an accident associated with maintenance,
inspection and repair work. For this reason, read the chapter "Safety
regulations" and the description of the "Residual risks during main
tenance, inspection and repair work" at the start of the chapter en
titled "Maintenance" (i.e. this chapter).

See also the maintenance cards:

Replacing the transfer tube bearing
Replacing the switching shaft bearing (flanged bearing)
Replacing the thrust ring and wear ring
Adjusting the S transfer tube

You should request the special fitting instructions from us if you have
a spectacle wear plate made from a special material (e.g. hard
metal, hard cast iron, ceramics).

No special tools required.

MA The tightening torques can be found in the corresponding

Spareparts list.

WK07_071_1109EN 597
 Maintenancecard
07−071
Page 2 of 14

Danger of crushing
A pressurized hydraulic system may cause the machine to move
suddenly, which may result in you being seriously injured if you are
working on the machine. To avoid risk, shut the machine down and
secure it against unauthorized or accidental starting.

Caution
Use only suitable lifting equipment for lifting components.

Note
Wear parts must be replaced in the event of one of the following:
 Severe wear is visible
 Concrete is seeping out

598 WK07_071_1109EN
 Maintenancecard
07−071
Page 3 of 14

When maintenance work is carried out, the machine must have been
shut down. The operations necessary for this task are described
below and must be carried out conscientiously. Perform all machine
functions using the remote control.

Shutting down the Proceed as follows to shut down the machine:

machine
" Switch off the engine.

" Dump the pressures completely.

Danger
Dump the accumulator pressure completely in systems with pressure
accumulators.

Starting up the The machine may be started up differently depending on the ma
machine chine model. When you are starting up a truck−mounted concrete
pump, proceed as follows:

" Unlock the EMERGENCY STOP button and sound the horn.

" Switch the engine on.

Caution
Do not switch the pump on until you are called upon to do so.

When you are starting up a stationary concrete pump, proceed as

follows:

" If there is a throttle, set it to one third.

" Start up the engine.

" Select a low output.

" Switch the pump on.

WK07_071_1109EN 599
 Maintenancecard
07−071
Page 4 of 14

Overview
1 2 3 4 5 1

6 6 6
WK07_071_1109EN 1

No. 0 Designation
1 Plunger cylinder
2 Switch lever
3 Clamping bolts with nuts
4 Switching shaft
5 Hexagon nut
6 Fastening bolts for spectacle wear plate

5100 WK07_071_1109EN
 Maintenancecard
07−071
Page 5 of 14

Removing the spec- The following describes how to remove the spectacle wear plate.
tacle wear plate
" Shut the machine down.

" Undo the hexagon nut(5) from the switching shaft(4), remove
the plunger cylinder(1) and undo the clamping bolts(3) on the
switch lever(2).
Maintenance card: Replacing the switching shaft bearing
(flanged bearing)

WK07_071_1109EN 2

Pushing the S transfer tube to one side

Note
If there is not enough space available for assembly, you can pull the
pressure connection towards the back.

" Push the S transfer tube away from the spectacle wear plate.

" Undo the eightfastening bolts (6) for the spectacle wear plate.

" Remove the spectacle wear plate from the hopper.

WK07_071_1109EN 5101
 Maintenancecard
07−071
Page 6 of 14

Replacing the inter-

mediate rings

1 2 3 4 5

WK07_071_1109EN 3

No. 0 Designation
1 Transition liner
2 Intermediate ring
3 Screw plug
4 Lubrication nipples
5 Grease gun

5102 WK07_071_1109EN
 Maintenancecard
07−071
Page 7 of 14

" Using a plastic−faced hammer, strike the old intermediate

ring(2) several times to remove any grout residue that could
block the intermediate ring(2) when it is being removed.

" Replace the screw plug(3) on the underside of the transition

liner(1) using the lubrication nipple(4) from the accessories.

" Connect a grease gun(5) to the lubrication nipple(4).

" Keep pumping in grease until the intermediate ring(2) is

pressed out.

WK07_071_1109EN 4

Leave the bore open

" Remove the lubrication nipple(4) again.

å This will prevent an air cushion from being formed when the
new intermediate ring(2) is inserted, allowing you to insert the
intermediate ring(2) more easily.

" Clean the surface thoroughly. Remove all concrete and grout
residue.

WK07_071_1109EN 5103
 Maintenancecard
07−071
Page 8 of 14

1 2 3
WK07_071_1109EN 5

No. 0 Designation
1 Intermediate ring
2 O−rings
3 Transition liner

" Slide in two O−rings(2) over the mounting surface of the new
intermediate ring(1).

" Grease the mounting surface of the new intermediate ring(1).

" Insert the new intermediate ring(1) into the transition liner(3).

5104 WK07_071_1109EN
 Maintenancecard
07−071
Page 9 of 14

" Using a plastic−faced hammer, tap the intermediate ring(1)

fully into the transition liner(3).

" Replace the second intermediate ring(1) in the same way.

WK07_071_1109EN 6

Fitting the O−ring

" Insert one O−ring (2) into the recess at the front of the inter
mediate ring(1).

Fitting the spectacle The following describes how to insert the spectacle wear plate.
wear plate

" Fit the new spectacle wear plate.

WK07_071_1109EN 5105
 Maintenancecard
07−071
Page 10 of 14

1 1

2 3

ÉÉÉÉÉÉ
ÉÉÉÉÉÉ
ÉÉÉÉÉÉ
ÉÉÉÉÉÉ
4 5 6 7

WK07_071_1109EN 7

No. 0 Designation
1 Fastening bolts on the left and right
2 Spectacle wear plate
3 Fastening bolts at the top and bottom
4 Intermediate ring
5 O−ring
6 Hopper wall
7 Clearance

5106 WK07_071_1109EN
 Maintenancecard
07−071
Page 11 of 14

Caution
The spectacle wear plate(2) only touches the O−rings(5) in the in
termediate rings(4). There is a small gap (7) between the spectacle
wear plate(2) and hopper wall (6). For this reason, only tighten the
fastening bolts(1) on the left and right finger−tight at first, because
otherwise the spectacle wear plate(2) will be distorted.

" Fit the new spectacle wear plate(2).

" Using the fastening bolts on the left and right(1), screw on the
new spectacle wear plate(2) finger−tight.

Note
If you have a ceramic spectacle wear plate(2), please contact our
After Sales department to enquire about the tightening torques.

" Using the fastening bolts at the top and bottom (3), screw on
the spectacle wear plate(2) to the appropriate tightening
torque.

Caution
Take care to ensure that the spectacle wear plate(2) does not be
come distorted.

" Using the fastening bolts on the left and right (1), screw on the
spectacle wear plate(2) to the appropriate tightening torque.

WK07_071_1109EN 5107
 Maintenancecard
07−071
Page 12 of 14

WK07_071_1109EN 8

Close the fitting bore

Caution
The fitting bores must be closed to prevent any dirt penetration.

To seal the pulling bores, only use the screw plugs, and not the lu
brication nipples. Otherwise, there is a risk that you will accidentally
lubricate these lubrication nipples as well while lubricating the ma
chine. Over time, this would push out the intermediate rings, and the
spectacle wear plate would be distorted.

" After inserting the new intermediate rings and spectacle wear
plate, seal the pulling bores again using the screw plugs.

5108 WK07_071_1109EN
 Maintenancecard
07−071
Page 13 of 14

" Replace the thrust ring and wear ring.

Maintenance card: Replacing the thrust ring and wear ring

" Fit the transfer tube bearing.

Maintenance card: Replacing the transfer tube bearing

" Insert the plunger cylinder.

Maintenance card: Replacing the switching shaft bearing
(flanged bearing)

" Adjust the S transfer tube so that it switches correctly.

Maintenance card: Adjusting the S transfer tube

WK07_071_1109EN 5109
 Maintenancecard
07−071
Page 14 of 14

5110 WK07_071_1109EN
 Maintenancecard
07−072
Page 1 of 8

07–072 Replacing the This maintenance card describes how to replace the S transfer tube.
S transfer tube You will find the maintenance intervals in the maintenance summary
at the start of this chapter.

Note
There are specific risks of an accident associated with maintenance,
inspection and repair work. For this reason, read the chapter "Safety
regulations" and the description of the "Residual risks during main
tenance, inspection and repair work" at the start of the chapter en
titled "Maintenance" (i.e. this chapter).

See also the maintenance cards:

Replacing the transfer tube bearing
Replacing the switching shaft bearing (flanged bearing)
Replacing the S transfer tube wear sleeve
Replacing the thrust ring and wear ring
Adjusting the S transfer tube
Measuring the wall thickness
Measuring the wall thickness of the double−layer pipe

No special tools required.

MA The tightening torques can be found in the corresponding

Spareparts list.

WK07_072_1109EN 5111
 Maintenancecard
07−072
Page 2 of 8

Danger of crushing
A pressurized hydraulic system may cause the machine to move
suddenly, which may result in you being seriously injured if you are
working on the machine. To avoid risk, shut the machine down and
secure it against unauthorized or accidental starting.

Caution
Use only suitable lifting equipment for lifting components.

Note
Wear parts must be replaced in the event of one of the following:
 Severe wear is visible
 Concrete is seeping out

We recommend that the switch lever also be replaced when the S

transfer tube is replaced. Practical experience has shown that the
toothing on the switching shaft and that on the switch lever wear to
gether as a result of the forces generated during switchover. Dam
age may be caused by an imprecise fit if only one component is re
placed.

Maintenance card: Replacing the switching shaft bearing

(flanged bearing)

5112 WK07_072_1109EN
 Maintenancecard
07−072
Page 3 of 8

When maintenance work is carried out, the machine must have been
shut down. The operations necessary for this task are described
below and must be carried out conscientiously. Perform all machine
functions using the remote control.

Shutting down the Proceed as follows to shut down the machine:

machine
" Switch off the engine.

" Dump the pressures completely.

Danger
Dump the accumulator pressure completely in systems with pressure
accumulators.

Starting up the The machine may be started up differently depending on the ma
machine chine model. When you are starting up a truck−mounted concrete
pump, proceed as follows:

" Unlock the EMERGENCY STOP button and sound the horn.

" Switch the engine on.

Caution
Do not switch the pump on until you are called upon to do so.

When you are starting up a stationary concrete pump, proceed as

follows:

" If there is a throttle, set it to one third.

" Start up the engine.

" Select a low output.

" Switch the pump on.

WK07_072_1109EN 5113
 Maintenancecard
07−072
Page 4 of 8

S transfer tube vari-

ants

1 2

WK07_072_1109EN 1

No. 0 Designation
1 S transfer tube with bolted switching shaft
2 S transfer tube with welded switching shaft

Note
Whichever variant of S transfer tube is fitted, the recommended pro
cedure for dismantling is as described below. The S transfer tube
with bolted switching shaft may also be dismantled and reassembled
in the hopper. The tube is then dismantled as described in the S
transfer tube with bolted switching shaft" maintenance card.

You should also consult the Divided hopper" maintenance card if

your machine has a divided hopper.

5114 WK07_072_1109EN
 Maintenancecard
07−072
Page 5 of 8

Removing the S Replace the S transfer tube if the wall thickness has fallen below the
transfer tube minimum.

Maintenance card: Measuring the wall thickness

Maintenance card: Measuring the wall thickness of the double−

layer pipe

" Shut the machine down.

" Attach suitable lifting gear to the S transfer tube.

" Remove the transfer tube bearing.

Maintenance card: Replacing the transfer tube bearing

" Remove the switching shaft bearing (flanged bearing).

Maintenance card: Replacing the switching shaft bearing
(flanged bearing)

WK07_072_1109EN 2

Removing the mixer shaft

" Remove the mixer shaft.

WK07_072_1109EN 5115
 Maintenancecard
07−072
Page 6 of 8

WK07_072_1109EN 3

Lifting out the S transfer tube

" Unbolt the scratch bar from the bottom of the S transfer tube.

" Push the S transfer tube forwards until the transfer tube outlet
is free.

" Lift the S transfer tube outlet opening first upwards and out.

Note
If just the wear sleeve is heavily worn, you can also replace just the
wear sleeve and then refit the S transfer tube.

Maintenance card: Replacing the wear sleeve on the S transfer

tube

" Fit the new S transfer tube. To do this, proceed in the reverse
order to removal.

5116 WK07_072_1109EN
 Maintenancecard
07−072
Page 7 of 8

" Fit a new thrust ring and a new wear ring.

Maintenance card: Replacing the thrust ring and wear ring

" Fit the switching shaft bearing (flanged bearing).

Maintenance card: Replacing the switching shaft bearing
(flanged bearing)

" Fit the transfer tube bearing.

Maintenance card: Replacing the transfer tube bearing

" Adjust the S transfer tube so that it switches correctly.

Maintenance card: Adjusting the S transfer tube

WK07_072_1109EN 5117
 Maintenancecard
07−072
Page 8 of 8

5118 WK07_072_1109EN
 Maintenancecard
07−073
Page 1 of 8

07–073 Replacing the This maintenance card describes how to replace the wear sleeve on
S transfer tube wear sleeve the S transfer tube. You will find the maintenance intervals in the
maintenance summary at the start of this chapter.

Note
There are specific risks of an accident associated with maintenance,
inspection and repair work. For this reason, read the chapter "Safety
regulations" and the description of the "Residual risks during main
tenance, inspection and repair work" at the start of the chapter en
titled "Maintenance" (i.e. this chapter).

See also the maintenance cards:

Replacing the transfer tube bearing
Replacing the switching shaft bearing (flanged bearing)

No special tools required.

MA The tightening torques can be found in the corresponding

Spareparts list.

WK07_073_1109EN 5119
 Maintenancecard
07−073
Page 2 of 8

Danger of crushing
A pressurized hydraulic system may cause the machine to move
suddenly, which may result in you being seriously injured if you are
working on the machine. To avoid risk, shut the machine down and
secure it against unauthorized or accidental starting.

Caution
Use only suitable lifting equipment for lifting components.

Note
Wear parts must be replaced in the event of one of the following:
 Severe wear is visible
 Concrete is seeping out

5120 WK07_073_1109EN
 Maintenancecard
07−073
Page 3 of 8

When maintenance work is carried out, the machine must have been
shut down. The operations necessary for this task are described
below and must be carried out conscientiously. Perform all machine
functions using the remote control.

Shutting down the Proceed as follows to shut down the machine:

machine
" Switch off the engine.

" Dump the pressures completely.

Danger
Dump the accumulator pressure completely in systems with pressure
accumulators.

Starting up the The machine may be started up differently depending on the ma
machine chine model. When you are starting up a truck−mounted concrete
pump, proceed as follows:

" Unlock the EMERGENCY STOP button and sound the horn.

" Switch the engine on.

Caution
Do not switch the pump on until you are called upon to do so.

When you are starting up a stationary concrete pump, proceed as

follows:

" If there is a throttle, set it to one third.

" Start up the engine.

" Select a low output.

" Switch the pump on.

WK07_073_1109EN 5121
 Maintenancecard
07−073
Page 4 of 8

Removing the wear If just the wear sleeve is heavily worn, you can replace it without hav
sleeve ing to replace the S transfer tube. You do not have to remove the S
transfer tube to do this.

" Shut the machine down.

" Remove the transfer tube bearing.

Maintenance card: Replacing the transfer tube bearing

" Loosen the hexagon nut on the switching shaft and the clamp
ing bolts on the switch lever.
Maintenance card: Replacing the switching shaft bearing
(flanged bearing)

Danger
There is a risk of burning during heating and fitting of the new wear
sleeve. Use suitable protective equipment.

5122 WK07_073_1109EN
 Maintenancecard
07−073
Page 5 of 8

1 2 3
WK07_073_1109EN 1

No. 0 Designation
1 Welds
2 Tube outlet
3 Wear sleeve

Removal when the S If the S transfer tube has been fitted, proceed as follows:
transfer tube is fitted
" Weld a metal pin onto the wear sleeve.

Caution
When cutting open the welds, take care not to damage the S transfer
tube.

" Carefully cut open the welds (1) on the front face between the
S transfer tube outlet(2) and wear sleeve(3) using an angle
grinder.

" Heat up the wear sleeve(3) evenly to approx. 140°C.

WK07_073_1109EN 5123
 Maintenancecard
07−073
Page 6 of 8

" Using a hammer, strike the metal pin to release the wear
sleeve.

" Remove the wear sleeve(3).

Removal when the S If the S transfer tube has been removed, proceed as follows:
transfer tube has been
removed Caution
When cutting open the welds and wear sleeve, take care not to dam
age the S transfer tube.

" Carefully cut open the welds (1) on the front face between the
S transfer tube outlet(2) and wear sleeve(3) using an angle
grinder.

" Heat up the wear sleeve(3) evenly to approx. 140°C.

" Cut open the wear sleeve carefully using an angle grinder.

" Remove the wear sleeve(3).

5124 WK07_073_1109EN
 Maintenancecard
07−073
Page 7 of 8

Fitting a wear sleeve

1 2
WK07_073_1109EN 2

No. 0 Designation
1 Wear sleeve
2 Tube outlet

Note
The wear sleeve(1) is chrome−plated, and must not therefore be
heated unevenly or too intensively.

" Heat up the new wear sleeve(1) evenly to approx. 140_C.

" Place the heated wear sleeve(1) over the tube outlet (2) and
allow the wear sleeve(1) to cool.

" On the front face, evenly position four welds between the wear
sleeve(1) and tube outlet(2).

" Grind the four welds.

WK07_073_1109EN 5125
 Maintenancecard
07−073
Page 8 of 8

" Fit the transfer tube bearing.

Maintenance card: Replacing the transfer tube bearing

" Tighten the hexagon nut on the switching shaft and the clamp
ing bolts on the switch lever.
Maintenance card: Replacing the switching shaft bearing
(flanged bearing)

5126 WK07_073_1109EN
 Maintenancecard
07−074
Page 1 of 6

07–074 Replacing the thrust ring This maintenance card describes how to replace the thrust ring and
and wear ring wear ring on the S transfer tube. You will find the maintenance inter
vals in the maintenance summary at the start of this chapter.

Note
There are specific risks of an accident associated with maintenance,
inspection and repair work. For this reason, read the chapter "Safety
regulations" and the description of the "Residual risks during main
tenance, inspection and repair work" at the start of the chapter en
titled "Maintenance" (i.e. this chapter).

See also the maintenance cards:

Replacing the transfer tube bearing
Replacing the switching shaft bearing (flanged bearing)
Replacing the spectacle wear plate
Adjusting the S transfer tube

No special tools required.

MA The tightening torques can be found in the corresponding

Spareparts list.

WK07_074_1109EN 5127
 Maintenancecard
07−074
Page 2 of 6

Danger of crushing
A pressurized hydraulic system may cause the machine to move
suddenly, which may result in you being seriously injured if you are
working on the machine. To avoid risk, shut the machine down and
secure it against unauthorized or accidental starting.

Caution
Use only suitable lifting equipment for lifting components.

Note
Wear parts must be replaced in the event of one of the following:
 Severe wear is visible
 Concrete is seeping out

5128 WK07_074_1109EN
 Maintenancecard
07−074
Page 3 of 6

When maintenance work is carried out, the machine must have been
shut down. The operations necessary for this task are described
below and must be carried out conscientiously. Perform all machine
functions using the remote control.

Shutting down the Proceed as follows to shut down the machine:

machine
" Switch off the engine.

" Dump the pressures completely.

Danger
Dump the accumulator pressure completely in systems with pressure
accumulators.

Starting up the The machine may be started up differently depending on the ma
machine chine model. When you are starting up a truck−mounted concrete
pump, proceed as follows:

" Unlock the EMERGENCY STOP button and sound the horn.

" Switch the engine on.

Caution
Do not switch the pump on until you are called upon to do so.

When you are starting up a stationary concrete pump, proceed as

follows:

" If there is a throttle, set it to one third.

" Start up the engine.

" Select a low output.

" Switch the pump on.

WK07_074_1109EN 5129
 Maintenancecard
07−074
Page 4 of 6

Removing the thrust To remove the thrust ring and wear ring, proceed as follows:
ring and wear ring
" Shut the machine down.

" Remove the transfer tube bearing.

Maintenance card: Replacing the transfer tube bearing

" Loosen the hexagon nut on the switching shaft and the clamp
ing bolts on the switch lever.
Maintenance card: Replacing the switching shaft bearing
(flanged bearing)

" Inspect the spectacle wear plate and replace it if required.

Maintenance card: Replacing the spectacle wear plate

5130 WK07_074_1109EN
 Maintenancecard
07−074
Page 5 of 6

1 2
WK07_074_1109EN 1

No. 0 Designation
1 Thrust ring
2 Wear ring

" Remove the old wear ring (2) and the old thrust ring (1).

Fitting the thrust ring To fit the thrust ring and wear ring, proceed as follows:
and wear ring
" Clean the thrust ring seat (1) thoroughly. Dirt and concrete resi
due must be removed from the seat.

" Fit the new thrust ring (1) and new wear ring (2) into the S
transfer tube.

" Fit the transfer tube bearing.

Maintenance card: Replacing the transfer tube bearing

" Adjust the S transfer tube so that it switches correctly.

Maintenance card: Adjusting the S transfer tube

WK07_074_1109EN 5131
 Maintenancecard
07−074
Page 6 of 6

5132 WK07_074_1109EN
 Maintenancecard
07−075
Page 1 of 14

07–075 Adjusting the This maintenance card describes how to adjust the S transfer tube.
S transfer tube This includes:
− prestressing the S transfer tube and
− adjusting the switching overlap between the wear ring and spec
tacle wear plate on the S transfer tube.

Note
There are specific risks of an accident associated with maintenance,
inspection and repair work. For this reason, read the chapter "Safety
regulations" and the description of the "Residual risks during main
tenance, inspection and repair work" at the start of the chapter en
titled "Maintenance" (i.e. this chapter).

See also the maintenance cards:

Replacing the switching shaft bearing (flanged bearing)

No special tools required.

MA The tightening torques can be found in the corresponding

Spareparts list.

WK07_075_1109EN 5133
 Maintenancecard
07−075
Page 2 of 14

Danger of crushing
A pressurized hydraulic system may cause the machine to move
suddenly, which may result in you being seriously injured if you are
working on the machine. To avoid risk, shut the machine down and
secure it against unauthorized or accidental starting.

Caution
Use only suitable lifting equipment for lifting components.

Note
Wear parts must be replaced in the event of one of the following:
 Severe wear is visible
 Concrete is seeping out

5134 WK07_075_1109EN
 Maintenancecard
07−075
Page 3 of 14

You will have to shut down and restart the machine a number of
times. The operations necessary for this task are described below
and must be carried out conscientiously. Perform all machine func
tions using the remote control.

Shutting down the Proceed as follows to shut down the machine:

machine
" Switch off the engine.

" Dump the pressures completely.

Danger
Dump the accumulator pressure completely in systems with pressure
accumulators.

Starting up the The machine may be started up differently depending on the ma
machine chine model. When you are starting up a truck−mounted concrete
pump, proceed as follows:

" Unlock the EMERGENCY STOP button and sound the horn.

" Switch the engine on.

Caution
Do not switch the pump on until you are called upon to do so.

When you are starting up a stationary concrete pump, proceed as

follows:

" If there is a throttle, set it to one third.

" Start up the engine.

" Select a low output.

" Switch the pump on.

WK07_075_1109EN 5135
 Maintenancecard
07−075
Page 4 of 14

Prestressing the S First, prestress the S transfer tube.

transfer tube
" Shut the machine down.

5 6 7 8

1 2 3 4
WK07_075_1109EN 1

No. 0 Designation
1 Spectacle wear plate
2 Wear ring
3 S transfer tube
4 Thrust ring
5 Gap
6 Hexagon nut
7 Retaining plate
8 Switch lever
9 Clamping bolts

Note
Make sure that the thrust ring (4) is not damaged when it is pressed
in.

" Unscrew the clamping bolts(9) from the switch lever(8).

5136 WK07_075_1109EN
 Maintenancecard
07−075
Page 5 of 14

" Tighten the hexagon nut(6) on the switching shaft so that the
wear ring(2) lies flat against the spectacle wear plate(1).

Note
A gap (5) must be maintained between the S transfer tube(3) and
wear ring(2) so that the S transfer tube(3) switches correctly.

" Check that the wear ring (2) makes contact with the spectacle
wear plate (1) on all sides.

" Slowly tighten the hexagon nut(6) by half a turn.

å The thrust ring (4) is then compressed by 1.5mm.
å The gap (5) between the S transfer tube(3) and wear
ring(2) is set.

" Ensure that one surface on the hexagon nut(6) is horizontal at

the top so that the retaining plate(7) can be refitted.

" Fit the retaining plate(7).

Note
Use only new nuts for the clamping bolts (9).

" Insert the clamping bolts (9) into the switch lever (8) and fit
new nuts.

" Tighten the clamping bolts(9) to the required torque.

" Further assembly is carried out in the reverse sequence to dis

assembly.
Maintenance card: Replacing the switching shaft bearing
(flanged bearing)

" Check that all covers and other safety equipment have been
refitted and are fully functional.

WK07_075_1109EN 5137
 Maintenancecard
07−075
Page 6 of 14

Setting the switching The switching overlap is set to the optimum if the wear ring is central
overlap to the relevant hole in the spectacle wear plate for both switch posi
tions of the S transfer tube. In other words, the swing angle of the S
transfer tube must not be either too great or too small.

Spectacle wear plate

with wear ring
1 2

WK07_075_1109EN 2

No. 0 Designation
1 Swing angle too great
2 Swing angle too small
3 Optimum swing angle

The left−hand switching overlap is corrected by replacing the pack

ing washer behind the ball cup on the right−hand plunger cylinder
with a thicker or thinner one as required. The right−hand switching
overlap is corrected on the left in the same way.

5138 WK07_075_1109EN
 Maintenancecard
07−075
Page 7 of 14

1 2 3

WK07_075_1109EN 3

No. 0 Designation
1 Plunger cylinder
2 Ball cup
3 Packing washer

" Start the machine up.

WK07_075_1109EN 4

Plunger cylinder extended

" Allow one plunger cylinder to retract completely.

" Shut the machine down.

WK07_075_1109EN 5139
 Maintenancecard
07−075
Page 8 of 14

WK07_075_1109EN 5

No. 0 Designation
1 Marking the spectacle wear plate

" Use a felt tip pen or oil chalk to mark the position of the wear
ring on the spectacle wear plate.

" Start the machine up.

" Allow the other plunger cylinder to retract.

" Shut the machine down.

" Determine to which side and by how many millimetres the

circle you have drawn is offset against the circle of the spec
tacle wear plate.

5140 WK07_075_1109EN
 Maintenancecard
07−075
Page 9 of 14

Spectacle wear plate

with sample markings

1 2

WK07_075_1109EN 6

No. 0 Designation
1 Packing washer too thin
2 Packing washer too thick
3 Optimum packing washer

To decrease the swing angle of the Stransfer tube by 4mm, the

fitted packing washer must be replaced by one which is 2mm
thicker.
To increase the swing angle of the Stransfer tube by 4mm, the fitted
packing washer must be replaced by one which is 2mm thinner.

WK07_075_1109EN 5141
 Maintenancecard
07−075
Page 10 of 14

1 2

WK07_075_1109EN 7

No. 0 Designation
1 Plunger cylinder
2 Locking plate

" Remove the locking plate(2) of the extended plunger cylin

der(1).

10300800

Removing the plunger cylinders

Note
The plunger cylinders can be pushed back as illustrated. It is, how
ever, also possible to screw a bolt into the jacking bores for the ball
cups and to push the plunger cylinders out with the ball cups.

5142 WK07_075_1109EN
 Maintenancecard
07−075
Page 11 of 14

" Force the piston of the extended plunger cylinder back a little
and remove the plunger cylinder with the hydraulic hoses.

1 2

WK07_075_1109EN 8

No. 0 Designation
1 Ball cup
2 Packing washer

" Remove the hexagon ball cup (1) along with the packing
washer (2).

Caution
No packing washers (2) may be inserted in the switch lever, as other
wise the plunger cylinder can run over the edge of the ball cup (1)
and break it.

" As required, fit a thicker or thinner packing washer (2) with the
ball cup (1).

" Fit the plunger cylinder and locking plate.

" Start the machine up.

WK07_075_1109EN 5143
 Maintenancecard
07−075
Page 12 of 14

" Allow the Stransfer tube to switch over a few times. Stoppen
Sie, wenn die S−Rohrweiche auf der noch nicht markierten Bril
lenplattenseite steht.

" Shut the machine down.

" Check the switching overlap of the other side of the spectacle
wear plate and correct accordingly.

Switching overlap on The two plunger cylinders must extend to the same extent on ma
VHS control chines with fully hydraulic control (VHS) and active signal tapping in
the plunger cylinders.

20300703

Plunger cylinder extended

" First set a switching overlap of the wear ring and the spectacle
wear plate.

" Allow the plunger cylinder (1) to extend to its end position.

" Shut the machine down.

" Measure how far the plunger cylinder has extended. (Measure
ment E1)

" Start the machine up.

5144 WK07_075_1109EN
 Maintenancecard
07−075
Page 13 of 14

" Allow the plunger cylinder (2) to extend to its end position.

" Shut the machine down.

" Measure how far the plunger cylinder has extended. (Measure
ment E2)

" Compare the two measurements.

The two measurements E1 and E2 should be identical. You will have

to change the packing washers as described below if the two
measurements are not equal:

" Swap the packing washer on the plunger cylinder with the
greater measurement for a washer (E1−E2):2 thinner.

" Swap the packing washer on the plunger cylinder with the
smaller measurement for a washer (E1−E2):2 thicker.

Note
This setting must be checked after a running−in period of approxi
mately 100 operating hours.

WK07_075_1109EN 5145
 Maintenancecard
07−075
Page 14 of 14

5146 WK07_075_1109EN
 Maintenancecard
10−007
Page 1 of 6

10–007 Measuring the wall thick- This maintenance card describes how to measure the wall thickness
ness (Machines with of delivery lines. You will find the maintenance intervals in the main
S transfer tube) tenance summary at the start of this chapter.

Note
There are specific risks of an accident associated with maintenance,
inspection and repair work. For this reason, read the chapter "Safety
regulations" and the description of the "Residual risks during main
tenance, inspection and repair work" at the start of the chapter en
titled "Maintenance" (i.e. this chapter).

No further maintenance cards required.

The following special tools are required:

Wall thickness measuring device

MA The tightening torques can be found in the corresponding

Spareparts list.

WK10_007_1109EN 5147
 Maintenancecard
10−007
Page 2 of 6

Note
Delivery lines are subject to constant wear. Measurement of the wall
thickness is particularly important before starting on large jobs.
You will obtain reliable results for your measurements if you carry out
the test with the measuring device recommended by Putzmeister.

Danger of explosion
The delivery line can burst once it reaches a high delivery pressure if
the wall thickness of the delivery line has decreased below the mini
mum required, particularly if a blockage has built up.

5148 WK10_007_1109EN
 Maintenancecard
10−007
Page 3 of 6

Caution
Only tap the delivery line with a piece of hardwood (hammer handle).
Otherwise, dents may be created and these will lead to more rapid
wear. In addition, the hardened lining of high wear resisting pipes
may flake off the inside of the pipe. The pipe can burst at points that
have suffered heavy wear.

11000101

Tapping the delivery line with a hammer handle

Straight pipes Uniform wear can be achieved by regularly rotating the straight de
livery pipes through 120°.
The minimum wall thickness for straight pipes is shown in the graph
below.

Bends Uniform wear can be achieved by regularly rotating the bends

through 180°. The wear on the external radius of a bend is greater
than that on the internal radius or on straight pipes. You should,
therefore, take special care when measuring the wall thickness of the
external radius of a bend.
The minimum wall thickness for bends is shown in the graph below.

11000200

Rotate delivery pipes and bends regularly

WK10_007_1109EN 5149
 Maintenancecard
10−007
Page 4 of 6

S transfer tube The minimum wall thickness for the S transfer tube depends on the
maximum possible operating pressure. Furthermore, the fact that the
S transfer tube is subject to greater stress at the point at which the
torque is applied (switching shaft − S transfer tube) must be taken
into consideration.

WK10_007_1109EN 1

X = Area of heavy loading

Operating pressure up to Guide value for wall thick-

130 bar ness

AreaA 8−10mm
AreaB 6−8mm

Note
We should draw your attention to the fact that the S transfer tube is
subject to varying loading as a result of the dynamic loading during
pumping. There is no general method for calculating the minimum
wall thickness for this loading, which depends on the individual cir
cumstances, and so the S transfer tube can also burst at an operat
ing pressure which is assumed still to be permissible.

You should also note that the operating pressure can rise to the
maximum pressure in the event of a blockage, and in this case the
wall thickness may no longer be adequate.

If the operating pressure is higher than 130bar, you must ask

Putzmeister what the minimum wall thickness is.

5150 WK10_007_1109EN
 Maintenancecard
10−007
Page 5 of 6

Measuring Follow the Operating Instructions supplied with the measuring de
vice when carrying out measurements. Do not measure the wall
thickness of the delivery line at just one point, but around the entire
circumference of the delivery pipes.
The minimum wall thickness is shown in the graph below.

Caution
Pipes and bends must be replaced as soon as the wall thickness
has declined to the value for the minimum wall thickness.
Putzmeister accepts no liability if the wall thickness is less than the
minimum wall thickness.

Note
As a rule it is possible to continue pumping with an operating pres
sure lower than that shown in the graph.

We should, however, draw your attention to the fact that the delivery
line is subject to varying loading as a result of the dynamic loading
during pumping. There is no general method for calculating the mini
mum wall thickness for this loading, which depends on the individual
circumstances, and so the delivery line can also burst at an operat
ing pressure which is assumed still to be permissible.

Furthermore, the operating pressure can rise to 85 bar in the event of

blockages, meaning that the wall thickness will no longer be ad
equate and the delivery line will burst.

WK10_007_1109EN 5151
 Maintenancecard
10−007
Page 6 of 6

Graph Minimum wall thickness as a function of operating pressure

1 High pressure
2 Maximum delivery pressure

5152 WK10_007_1109EN
 Maintenancecard
10−044
Page 1 of 2

10–044 Measuring the wall thick- This maintenance card describes how to measure the wall thickness
ness of two–layer pipes of two−layer delivery lines.

Note
There are specific risks of an accident associated with maintenance,
inspection and repair work.
For this reason, read the chapter "Safetyregulations" and the
description of the "Residual risks during maintenance, inspection
and repair work" at the start of the chapter entitled "Maintenance"
(i.e. this chapter).

See also the maintenance cards:

Measuring the wall thickness

The following special tools are required:

Wall thickness measuring device, material no. 454460

Note
Observe all safety instructions in the machine−specific Operating
Instructions and in the Safety manual.

Danger of explosion
You must not open or tap delivery lines while these are pressurized.
Concrete exiting under pressure can cause injury. The concrete column
must be depressurized by reverse pumping before the delivery line
is opened. Never work bending directly over the coupling.

WK10_044_1109EN 5153
 Maintenancecard
10−044
Page 2 of 2

Inspecting two–layer Inspect two−layer delivery pipes and delivery line elbows
delivery pipes and (DN125,max. concrete pressure 85 bar) as follows:
delivery line elbows
" Visual inspection for cracks. Replace in case of crack
formation.

" Measure the wall thickness at the measuring points P1 and P 2.

Replace if the wall thickness has fallen below the minimum
required (see table).

Type Minimum (mm)

No. DN 125
P1 P2
up to 85 bar
Twin Pipe Twin Cast
1.1 7.1 + 3.6 4.1 3.6
Delivery line elbow
1.2 7.0 + 2.0 7.0 3.0
2.1 2.5 + 2.0 2.5 3.3
2.2 2.5 + 2.0 2.5 4.9
Delivery pipe
2.3 5.6 + 3.0 3.7 3.7
2.4 5.6 + 3.0 3.7 3.1

1.1 – 1.2
Delivery line elbow
Measuring points
P1/P2
Minimum (seetable)

2.1 – 2.4
Delivery pipe
Measuring points
P1/P2
Minimum (seetable)

Extract from Esser Service Manual – EM 070190, see Technical Appendix

5154 WK10_044_1109EN
 Maintenancecard
20−074
Page 1 of 2

20–074 Lubricating the placing This maintenance card describes how to lubricate all lubrication
boom (M 38 RZ) points on the placing boom if you do not have a centralized lubrica
tion system. You will find the maintenance intervals in the mainten
ance summary at the start of this chapter.

No further maintenance cards required.

The following special tools are required:

Grease gun

Note
Use a grease with the marking K2K in accordance with DIN51502,
NLGI Class2.

Lubrication intervals You should grease the lubrication points every 60hours unless a dif
ferent interval is specified. You should apply the grease until you can
see it emerging.

WK20_074_1212EN 1

Lubrication diagram for M38RZ placing boom

WK20_074_1212EN 5155
 Maintenancecard
20−074
Page 2 of 2

5156 WK20_074_1212EN
 Maintenancecard
21−058
Page 1 of 2

21–058 Lubricating the boom This maintenance card describes the lubrication of all lubrication
pedestal (TRDI 80) points on the boom pedestal if you do not have a centralized lubrica
tion system. You will find the maintenance intervals in the mainten
ance summary at the start of this chapter.

Note
There are specific risks of accidents associated with maintenance,
inspection and repair work. For this reason, read the chapter Safety
regulations" and the description of the Residual risks during main
tenance, inspection and repair work" at the start of the chapter en
titled Maintenance" (i.e.this chapter).

No further maintenance cards required.

The following special tools are required:

Grease gun

Note
Use a grease with the marking K2K in accordance with DIN51502,
NLGI Class2.

Lubrication intervals You should grease the lubrication points daily, unless a different in
terval is specified. You should apply the grease until you can see it
emerging.

WK21_058_1212EN 5157
 Maintenancecard
21−058
Page 2 of 2

Lubrication points with central lubrication manifold

1
2

1 2

WK21_058_1212EN 1

Lubrication diagram for TRDI80 boom pedestal

1 Snaplock
2 Lubrication nipple strip

5158 WK21_058_1212EN
 Maintenancecard
21−001
Page 1 of 2

21–001 Checking connecting bolts This maintenance card describes inspection of the connecting bolts
on the slewing ring on the slewing ring. Check the connecting bolts on the slewing ring
in accordance with the Inspection intervals for retesting" (see the
Safety regulations" chapter in the operating instructions).

No further maintenance cards required.

No special tools required.

Danger
Lethal danger caused by falling arm assembly.

If connecting bolts on the slewing ring are loose, the connection

point may tear and the arm assembly fall down.

Have the connecting bolt replaced immediately, and only by quali

fied personnel authorized by Putzmeister.

Note
There are specific risks of accident associated with maintenance,
inspection and repair work. For this reason, read the chapter
Safetyregulations" and the description of the Residualrisks during
maintenance, inspection and repair work" at the start of the chapter
entitled Maintenance" (i.e.this chapter).

WK21_001_1403EN 5159
 Maintenancecard
21−001
Page 2 of 2

Note
If a connecting bolt is loose, the two connecting bolts to the left and
the two connecting bolts to the right must also be replaced.

WK21_001_1403EN 1

Pos.0 Designation
1 outer connecting bolts
2 inner connecting bolts

" Tap the connecting bolts on the outer and inner ring with a
hammer.
å A dull sound means that the bolt is loose. A clear sound
means that the bolt is firmly in place.

" If you have determined that the connecting bolt is loose,

havethe connecting bolt replaced immediately, and only by
qualified personnel authorized by Putzmeister.

5160 WK21_001_1403EN
 Maintenancecard
25−001
Page 1 of 12

25–001 Replacing the delivery line This maintenance card describes how to replace the delivery line
and its seals. You will find the maintenance intervals in the mainten
ance summary at the start of this chapter.

Note
There are specific risks of an accident associated with maintenance,
inspection and repair work. For this reason, read the chapter "Safety
regulations" and the description of the "Residual risks during main
tenance, inspection and repair work" at the start of the chapter en
titled "Maintenance" (i.e. this chapter).

See also the maintenance cards:

Measuring the wall thickness

The following special tools are required:

Feeler gauge 4mm

MA The tightening torques can be found in the corresponding

Spareparts list.

WK25_001_1109EN 5161
 Maintenancecard
25−001
Page 2 of 12

General The delivery line is subdivided into two divisions:

− boom delivery line
− pump−boom delivery line

These comprise:
− elbows
− straight pipes of uniform length (maximum 3 m)
− adapter pipes (straight pipes manufactured individually for each
arm assembly in order to fit the delivery line to the arm lengths)

Wall thickness Measure the wall thickness of the delivery line to determine which
pipe sections need to be replaced.
Maintenance card: Measuring the wall thickness

The starting points for laying the pipe on the boom are the hinge
pivot points. The straight sections of the delivery line run from pivot
point to pivot point. They are no more than 3 m long. The delivery
line is matched to the arm length concerned by means of the
adapter pipes.
The length of the pump−boom delivery line is also adapted by
means of adapter pipes.

5162 WK25_001_1109EN
 Maintenancecard
25−001
Page 3 of 12

Adapter pipe length plate

10 15

11 16
1
12

2 13
14
3 17
18
4 19
20
5

WK25_001_1109EN 1

WK25_001_1109EN 5163
 Maintenancecard
25−001
Page 4 of 12

No. 0 Placing boom data

1 Model
2 Placing boom no.
3 Material no. (MN)
4 Year of manufacture
5 Horizontal reach max.
6 Vertical reach max.
7 Length of end hose max.
8 Hydraulic pressure max.
9 Delivery pressure max.
Placing boom delivery line data
10 MN (material number)
11 DN (nominal diameter)
Model (maximum permitted outside diameter
12
and wall thickness of the delivery line)
13 Coupling type (AL=aluminium, ST=steel)
14 L1−L6: Arm assembly adapter pipe lengths
End hose data
15 MN (material number)
16 DN (nominal diameter)
Pump delivery line data
17 MN (material number)
18 DN (nominal diameter)
Model (maximum permitted outside diameter
19
and wall thickness of the delivery line)
20 V1−V10: Pump−riser pipe adapter pipe lengths

5164 WK25_001_1109EN
 Maintenancecard
25−001
Page 5 of 12

Ordering The length of the adapter pipes differs according to the machine and
boom. For re−ordering purposes, you should take the lengths and
location of all the adapter pipes on your machine from the adapter
pipe length plate next to the rating plate or from the following spare
parts sheets:
− Boom delivery line: Spare parts sheet group 25.0
− Pump−boom delivery line: Spare parts sheet group 25.3

12501000

The adapter pipe length plate is located on the boom

When ordering adapter pipes you should always state:

− Machine number Example: 22/.....
− Mounting position L3.1
− Length in mm 1377 mm
− Diameter DN DN 125

Caution
You must not exceed the delivery line wall thickness specified on the
rating plate and in the machine card. The additional weight can im
pair the machine’s stability.

Note
Should you wish to re−equip your machine to a delivery line of
greater wall thickness, the stability of your machine will have to be
recalculated and checked and approved by an authorized inspector.

WK25_001_1109EN 5165
 Maintenancecard
25−001
Page 6 of 12

Tension– The boom delivery line must be fitted with the arm assembly fully re
free assembly lieved of tension:
− The arm assembly is not under tension in the driving position if
each arm is lying freely on the bearing surface provided for this
purpose.
− The arm assembly is not under tension when unfolded if each arm
is supported.

Caution
If the tension on the arm assembly is not fully relieved during fitting,
stresses may occur in the delivery line on movement of the placing
boom and consequential damage may be caused to the pipe
brackets and to the placing boom. Furthermore, the boom may
swing up and down during pumping operations causing the end
hose to swing violently and strike out.

Clearance A clearance of 4 mm must be maintained between the delivery pipes

over the whole of the delivery line, so that the weld−on rings can butt
against the couplings without play. This clearance is achieved either:
− automatically, through the use of a Cseal (triple−lip seal); or
− manually, by adjustment, using a feeler gauge.

5166 WK25_001_1109EN
 Maintenancecard
25−001
Page 7 of 12

Seal C seals (triple−lip seals) are used where the delivery line runs in a
straight line and there is no rotational movement. The 4 mm clear
ance is set automatically.

Caution
No triple−lip seals (Cseals) may be used in the pivot hinges of the
delivery line elbows.

A seals are used:

− if the delivery line does not run in a straight line;
− in the pivot hinges; and
− at the fitting coupling at the boom tip.
The spacing of 4 mm must be set using the feeler gauge.

Coupling Couplings with lever−operated closures must be secured with a

spring safety clip.

WK25_001_1109EN 2

Securing couplings with lever−operated closures

Couplings with a threaded closure are closed using self−locking

nuts. These nuts must not be re−used, but must be replaced each
time the coupling is fitted.

Caution
You must not fit aluminium couplings in the pivot hinges of the delivery
line elbows. Aluminium couplings have a higher wear rate than steel
couplings and are worn away more quickly by the rotational move
ment.

WK25_001_1109EN 5167
 Maintenancecard
25−001
Page 8 of 12

Fitting an A seal

4mm

11000301

Set the spacing with the feeler gauge

" Push the A seal over the fixed delivery line pipe.

" Lay the pipe to be attached in the pipe bracket and push it up
to the fixed pipe.

" Set the spacing of 4mm between the pipes using a feeler
gauge.

" Fix the pipe to be attached in the pipe brackets.

" Push the A seal over the two weld−on rings.

" Fit the coupling and secure it.

5168 WK25_001_1109EN
 Maintenancecard
25−001
Page 9 of 12

Caution
No triple−lip seals (Cseals) may be used in the pivot hinges.

Fitting a C seal

4mm

11000302

The spacing is set automatically by the seal ring

" Push the C seal over the weld−on ring of the fixed delivery line
pipe.

" Lay the pipe to be attached in the pipe bracket and push it up
to the fixed pipe.

" Push the pipe to be attached as far as the stop in the seal ring.

" Fix the pipe to be attached in the pipe brackets.

" Fit the coupling and secure it.

WK25_001_1109EN 5169
 Maintenancecard
25−001
Page 10 of 12

Boom delivery line The starting points for laying the pipe on the boom are the hinge
pivot points.

" Grease all couplings and seals well internally before assembly.

Note
Use a lithium soap base multipurpose grease labelled K2K.

" Install the elbows in the fitting couplings at the pivot points.

" Align the elbows such that the straight pipes can be connected
without tension.

" Fix the elbows.

" Install the fixed length delivery pipes.

" Install the adapter pipes last.

5170 WK25_001_1109EN
 Maintenancecard
25−001
Page 11 of 12

Pump–boom delivery The pressure pipe is the starting point for assembly.
line
Note
You should use only high−pressure pipes when replacing these de
livery line pipes.
Only Cseals (triple−lip seals) are used throughout the pump−boom
delivery line.

" Grease all couplings and seals well internally before assembly.

Note
Use a lithium soap base multipurpose grease labelled K2K.

" Fit the reducer pipe to the pressure pipe with a clamp coupl
ing. The clamp coupling must be capable of rotating with the
pressure pipe. The reducer pipe, which must be located in a
vibration absorber, may not also turn.

" Fit the boom connection pipes as far as the elbow on the riser
pipe.

WK25_001_1109EN 5171
 Maintenancecard
25−001
Page 12 of 12

5172 WK25_001_1109EN
 6 Index of key words

In this section you will find the most important key words with the
number of the page on which you will find the key word as a heading
in the left margin. This Index of key words is listed alphabetically by
the main concepts. These are subdivided into associated sub−con
cepts, marked with a dash.

BP11_001_0201EN

A  Exhaust, 2  11
Accumulator, 4  1
Accumulator dump valve, 4  1
 Emergency operation, 4  8
Agitator, Emergency operation, 4  3
Agitator gearbox, Transmission oil,
5  14
Agitator safety cutout
 Acknowledge, 3  9
 Checking the safety function, 3  6
 Description of the functions, 3  7
 Function check, 3  8
 Unexpected restart, 3  9
B E
Boom control block, Description of
the functions, 3  13
Boom function, Emergency operation,
4  10
C Emergency operation
Cable remote control, Checking the
safety function, 3  12
Cardan shaft
 Cleaning, 5  33
 Inspection, 5  32
 Lubricating, 5  33
Centralized lubrication system
 Grease, 5  15
 Low temperature grease, 5  15
Cleaning, Cardan shaft, 5  33
Components
 Electrical components, 2  8
 Safetyrelevant components, 2  5
Control block
 Boom, 4  5, 4  10, 4  16
 Support, 4  12, 4  19
Control devices
 Accumulator dump valve, 4  1, 4  8
 Agitator valve, 4  3
 Boom control block, 4  5, 4  10, 4  16
 Emergency operation − delivery cylin
der, 4  1, 4  8
 Emergency operation − transfer tube,
4  1, 4  8
 Pump control system, 4  1, 4  8
 Support control block, 4  12, 4  19
Indexofkeywords
Copyright, 1  2
D Function checks, 5  41
Delivery cylinder, Emergency opera-
tion, 4  1, 4  8
Delivery line
 Measuring the wall thickness, 5  153
 Measuring the wall thickness (Machi
nes with S transfer tube), 5  147
 Replacing, 5  161
Delivery piston, Piston replacement
on the dual piston end–of–travel
positioning system, 5  61
Disposal, Machine, 2  12
Electrical components, 2  8
Electrical power, 2  7
 Power at the construction site, 2  8
Emergency control levers, Boom
function, 4  5
 Agitator and water pumps, 4  3
 Boom function, 4  10, 4  16
 Delivery cylinder, 4  1, 4  8
 Support function, 4  12, 4  19
 Transfer tube, 4  1, 4  8
EMERGENCY STOP function
 Checking the safety function, 3  4
 Description of the functions, 3  4
 Function check, 3  5
Emergency supply, Connecting an ex-
ternal hydraulic power pack, 4  14
Exhaust fumes, 2  11
F Lubricant recommendation
Faults, Recovering the machine, 4  7
Filter change
 Vacuum filter, 5  51
 Vacuum return flow filter, 5  51
 Ventilation filter, 5  47
Flanged bearing, Replacing, 5  81
Flared screwed joint, 5  8
Full fluid change, Transfer gearbox,
5  23
Fumes
 Noise, 2  10
Functional fluids, 2  11, 5  9
G
Grille
 Checking the safety function, 3  18
 Description of the functions, 3  18
 Function check, 3  19
H
Hydraulic fluid, Full fluid change,
5  35
Hydraulic hoses, 2  10
 Maintenance, 5  43
Hydraulic systems, 2  9
I
Icons, 1  3
Inspection, Cardan shaft, 5  32
Intermediate rings on the transition
liner, Replacing, 5  102
K
KEP, Piston end–of–travel positio-
ning, 5  61
L
Liability, Exclusion, 2  1
Lubricant analysis, 5  9, 5  11
 Agitator gearbox, 5  14
 Engine oil, 5  14
 General, 5  12
 Greases, 5  15
 Hydraulic fluids, 5  16
 Low temperature grease, 5  15
 Oils, 5  14
 Pump tube grease, 5  15
 Rotor gearbox, 5  14
 Slewing gear transmission, 5  14
 Transfer gearbox, 5  14
 Transmission oil, 5  14
i
 Indexofkeywords
Lubrication
 Cardan shaft, 5  33
 Grease, 5  15
 Placing boom M38RZ, 5  155
 S transfer tube, 5  71
 TRDI80 boom pedestal, 5  157
M 3  20
Maintenance and special work, 2  2
Maintenance cards
 Adjusting the S transfer tube, 5  133
 Changing the hydraulic fluid, 5  35
 Changing the ventilation filter element,
5  47
 Checking connecting bolts on the sle
wing ring, 5  159
 Delivery piston replacement on the
dual piston end−of−travel positioning
system, 5  61
 Function checks, 5  41
 Hydraulic fluid filter change, 5  51
 Hydraulic hoses, 5  43
 Inspecting the cardan shaft, 5  31
 Lubricating the cardan shaft, 5  31
 Lubricating the M38RZ placing
boom, 5  155
 Lubricating the S transfer tube, 5  71
 Lubricating the TRDI80 boom pede
stal, 5  157
 Lubrication, 5  155
 Measuring the wall thickness, 5  153
 Measuring the wall thickness (Machi
nes with S transfer tube), 5  147
 Replace the spectacle wear plate,
5  97
 Replacing the delivery line, 5  161
 Replacing the S transfer tube, 5  111
 Replacing the S transfer tube wear
sleeve, 5  119
 Replacing the switching shaft bearing
(flanged bearing), 5  81
 Replacing the thrust ring and wear
ring, 5  127
 Replacing the transfer tube bearing,
5  73
 Slewing gear transmission, 5  27
 Transfer gearboxes G64SB and
G64SC, 5  21
 Visual checks, 5  19
Maintenance intervals, 5  1
Measuring the wall thickness, 5  153
 Machines with S transfer tube, 5  147
ii
N  Replacing, 5  111
Noise emissions, 2  10
O Safety equipment, 2  6
Organizational measures, Plates, 3  1,
P  Protective devices, 3  16
Piston end–of–travel positioning,
2–KEP system, 5  61
Placing boom, Working on the pla-
cing boom, 2  5
Plates, Inspection, 3  20
Power, 2  8
Power at the construction site, 2  8
Profiled ring joint, 5  8
Protective devices, 3  16
 Grille, 3  18
Protective equipment, 2  6
Pump control system, 4  1
 Emergency operation, 4  8
Pump tube in rotor pumps, Grease,
5  15
R  Transmission oil, 5  14
Radio remote control, Checking the
safety function, 3  12
Recovering the machine, 4  7
 with onboard equipment, 4  8
Remote control, Checking the safety
function, 3  12
Remote control joysticks
 Checking the safety function, 3  12
 Description of the functions, 3  12
 Function check, 3  14
Rotor gearbox, Transmission oil, 5  14
Rotor pumps, Pump tube grease,
5  15
S
S transfer tube
 Adjusting, 5  133
 Lubrication, 5  71
 Measuring the wall thickness, 5  147
 Prestressing, 5  136
 Switching overlap, 5  138
S transfer tube wear sleeve, Repla-
cing, 5  119
 Active safety functions, 3  1
 Overview, 3  1
 Passive safety functions, 3  1
 Plates, 3  20
 Safetyrelated parts (SRPs), 3  2
Safety functions
 Active, 3  1
 Agitator safety cutout, 3  6
 EMERGENCY STOP function, 3  4
 Grille, 3  18
 Passive, 3  1
 Protective devices, 3  16
 Remote control joysticks, 3  12
 Support control block, 3  10
Safety regulations
 Basic principle, 2  1
 Exclusion of liability, 2  1
Safety-related parts (SRPs), 3  2
Safety-relevant components, 2  5
Slewing gear transmission
 Maintenance, 5  27
 Oil, 5  29
Slewing ring, Connecting bolts, 5  159
Software, 2  6
Special work, 2  2
Spectacle wear plate, Replacing, 5  97
SRP, 3  2
Support control block
 Checking the safety function, 3  10
 Description of the functions, 3  10
 Function check, 3  11
Support function, Emergency opera-
tion, 4  12, 4  19
Switching shaft bearing, Replacing,
5  81
Symbols, 1  3
T
Thrust ring, Replacing, 5  127
 Indexofkeywords

Tightening torques
 Flared screwed joint, 5  8
 General, 5  7
 Profiled ring joint, 5  8
 Set screws and nuts, 5  7
Transfer gearbox
 Full fluid change, 5  23
 Transmission oil, 5  14
Transfer tube, Emergency operation,
4  1, 4  8
Transfer tube bearing, Replacing,
5  73
Transfer tube damping, 4  1
Transition liner, Replacing the inter-
mediate rings, 5  102
Transmission oil
 Agitator gearbox, 5  14
 Rotor gearbox, 5  14
 Slewing gear transmission, 5  14
 Transfer gearbox, 5  14
TRDI 80, Lubrication, 5  157
Two–layer delivery line elbow, Inspec-
tion, 5  154
Two–layer delivery pipe, Inspection,
5  154

U
Unexpected restart, Agitator safety
cutout, 3  9

V
Visual checks, 5  19

W
Water pump, Emergency operation,
4  3
Wear ring, Replacing, 5  127
Welding, 2  4

iii