Operating Instructions

for machine operator and maintenance staff

always keep by the machine

Truck mixer
concrete pump PUMI 26.67 Q

Machine no. 270100254

05−07−15

The paper on which this document is printed is 100% chlorine free

Putzmeister Worldwide

Deutsch
Putzmeister AG +49−7127−599−0 pmw@pmw.de

land Max−Eyth−Strasse 10
PM D− 72631 Aichtal +49−7127−599−520 www.putzmeister.de

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

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

2.2.1 Inspection intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
2.3.4 Extending the reach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  11
2.3.5 Extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  12
2.3.6 Impermissible endhose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  12

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2.3.7 Impermissible working area . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  12

2.3.8 Climbing the placing boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  13
2.3.9 High−pressure delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  13

2.4 Exclusion of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 13

2.5 Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 14
2.5.1 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  14
2.5.2 Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  14
2.5.3 Responsibility of the machine operator . . . . . . . . . . . . . . . . . . 2  14

2.6 Operating Instructions, operating procedures

and other regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 15
2.6.1 Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  15
2.6.2 Operating procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  16
2.6.3 Other regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  16

2.7 Personal protective equipment . . . . . . . . . . . . . . . . . . . . . . . 2 — 17

2.8 Before starting work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 18

2.8.1 Checking that the machine is ready foroperation . . . . . . . . 2  18
2.8.2 Rendering the machine ready foroperation . . . . . . . . . . . . . 2  18

2.9 Danger due to high–voltage . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 20

2.9.1 High−voltage lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  20
2.9.2 Discharge voltage pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  20
2.9.3 Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  20
2.9.4 Procedure in the event of a flash over . . . . . . . . . . . . . . . . . . . 2  22
2.9.5 Electrostatic charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  23

2.10 Stationary machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 24

2.10.1 Set−up site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  24
2.10.2 Lifting machines andcomponents . . . . . . . . . . . . . . . . . . . . . . 2  24
2.10.3 Loading and transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  24

2.11 Mobile machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 25

2.11.1 Set−up site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  25
2.11.2 Supporting ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  26
2.11.3 Corner bearing loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  27
2.11.4 Supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  28
2.11.5 Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  30
2.11.6 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  31
2.11.7 Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  32

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2.12 Placing booms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 33

2.12.1 Unfolding the placing boom . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  33
2.12.2 End hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  35
2.12.3 Procedure in storms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  36
2.12.4 Concreting in coldweather . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  36

2.13 Delivery line systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 37

2.13.1 Suitable delivery lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  37
2.13.2 Securing delivery lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  37
2.13.3 Tightness and blockages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  38
2.13.4 Opening delivery lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  39
2.13.5 Clearance to delivery lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  39
2.13.6 Fastening delivery lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  39
2.13.7 Continuation delivery lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  39
2.13.8 Devices for shutting−off, diverting or
cleaning delivery lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  40

2.14 Pumping operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 41

2.14.1 Place of work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  41
2.14.2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  41
2.14.3 Remote control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  41
2.14.4 Moving machine components . . . . . . . . . . . . . . . . . . . . . . . . . . 2  42
2.14.5 Constant observation of the machine . . . . . . . . . . . . . . . . . . . 2  42
2.14.6 Truck mixer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  42

2.15 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 43
2.15.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  43
2.15.2 Cleaning agents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  44
2.15.3 Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  44
2.15.4 Cleaning with compressed air . . . . . . . . . . . . . . . . . . . . . . . . . 2  45
2.15.5 Protection against water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  45
2.15.6 Post−cleaning procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  45

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2.16 Requirements for special work . . . . . . . . . . . . . . . . . . . . . . . 2 — 46

2.17 Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 48

2.18 Working on the placing boom . . . . . . . . . . . . . . . . . . . . . . . . 2 — 49

2.19 Safety–relevant components . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 49

2.20 Protective and safety equipment . . . . . . . . . . . . . . . . . . . . . 2 — 50

2.21 Electrical power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 51

2.21.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  51
2.21.2 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  52
2.21.3 Power at the construction site . . . . . . . . . . . . . . . . . . . . . . . . . . 2  52

2.22 Hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 53

2.22.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  53
2.22.2 Replacing hydraulic hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  53

2.23 Noise emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 54

2.24 Exhaust fumes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 54

2.25 Functional fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 55

IV 270100254
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3 General technical description

3.1 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 1

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

3.3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 7

3.3.1 Electromagnetic compatibility (EMC) . . . . . . . . . . . . . . . . . . . 3  7
3.3.2 Machine rating plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  8
3.3.3 Boom rating plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  9
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 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  14
3.4.6 Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  15
3.4.7 Vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  17
3.4.8 Ventilation cock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  19

3.5 Electrical control devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 20

3.5.1 Control cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  21
3.5.2 Ergonic Graphic Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  23
3.5.3 Ergonic Output Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  45
3.5.4 High−pressure water pump dry−running cut−out . . . . . . . . . 3  48
3.5.5 Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  50
3.5.6 Control panel on the outside of the machine . . . . . . . . . . . . . 3  53
3.5.7 Cable control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  55
3.5.8 Radio control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  58
3.5.9 EMERGENCY SHUT−DOWN button . . . . . . . . . . . . . . . . . . . . . 3  65
3.5.10 Agitator safety cutout (RSA) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  68

3.6 Hydraulic control devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 69

3.6.1 Pump control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  70
3.6.2 Support control block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  72
3.6.3 Boom functions control block . . . . . . . . . . . . . . . . . . . . . . . . . . 3  75

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3.7 Other components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 77

3.7.1 End hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  78
3.7.2 Pressurized water system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  81
3.7.3 High−pressure waterpump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  82
3.7.4 Vibrator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  85
3.7.5 Hydraulic fluid radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  86
3.7.6 Chute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  89

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 — 8

VI 270100254
 Tableofcontents

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 Before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  3
5.1.4 NA power take−offs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  5
5.1.5 Operating and control elements for power take−offs . . . . . . 5  6
5.1.6 Starting the rotor pump up . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  8
5.1.7 Remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  9

5.2 Set–up site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 — 17

5.2.1 Space requirement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  18
5.2.2 Danger zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  19
5.2.3 Minimum clearance from pits . . . . . . . . . . . . . . . . . . . . . . . . . . 5  20
5.2.4 Safe clearance frompits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  21
5.2.5 Supporting ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  21
5.2.6 Support area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  23

5.3 Supporting the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 — 30

5.3.1 Working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  31
5.3.2 Remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  32
5.3.3 Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  33
5.3.4 Danger zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  34
5.3.5 Spirit level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  35
5.3.6 Forward support legs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  36
5.3.7 Forward support feet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  37
5.3.8 Rear support feet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  38
5.3.9 Remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  39

5.4 Function check on the pump . . . . . . . . . . . . . . . . . . . . . . . . . 5 — 40

5.4.1 Checking the vacuumgauge . . . . . . . . . . . . . . . . . . . . . . . . . . 5  41
5.4.2 Function check on the agitator safety cutout . . . . . . . . . . . . . 5  42
5.4.3 Filter functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  44
5.4.4 EMERGENCY SHUT−DOWN function . . . . . . . . . . . . . . . . . . . 5  46
5.4.5 Function check on the boom control block . . . . . . . . . . . . . . 5  48

270100254 VII
 Tableofcontents

5.5 Boom movements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 — 49

5.5.1 Restrictions on use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  50
5.5.2 Danger zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  51
5.5.3 Exceptional cases and emergencies . . . . . . . . . . . . . . . . . . . 5  55
5.5.4 Spontaneous retraction of the boom and support cylinders 5  56
5.5.5 Uncontrolled boom movements . . . . . . . . . . . . . . . . . . . . . . . . 5  57

5.6 Hand signals for boom and pumping operations . . . . . . 5 — 59

5.7 Extending the 3 Z boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 — 66

5.7.1 End hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  67
5.7.2 Arm 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  67
5.7.3 Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  68
5.7.4 Arm 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  68
5.7.5 Arm 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  69
5.7.6 Impermissible working range . . . . . . . . . . . . . . . . . . . . . . . . . . 5  70

5.8 Pumping operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 — 71

5.8.1 Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  71
5.8.2 Notes on correct pumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  74
5.8.3 Starting pumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  76
5.8.4 Pumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  77
5.8.5 Breaks in pumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  78
5.8.6 Possible faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  79
5.8.7 Restarting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  81
5.8.8 Special cases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  82

5.9 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 — 84
5.9.1 Delivery line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  91
5.9.2 Suction cleaning of the delivery line . . . . . . . . . . . . . . . . . . . . 5  93
5.9.3 High−pressure watercleaning . . . . . . . . . . . . . . . . . . . . . . . . . 5  95
5.9.4 Compressed air cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 100
5.9.5 Cleaning the hopper and rotor pump . . . . . . . . . . . . . . . . . . . 5 104
5.9.6 Truck superstructure and post−washing operations . . . . . . . 5 106

5.10 Driving position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 —114

5.10.1 Shift the placing boom to the driving position . . . . . . . . . . . . 5 114
5.10.2 Retracting the supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 115
5.10.3 Remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 116

VIII 270100254
 Tableofcontents

6 Maintenance
6.1 Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 1

6.2 General tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 3

6.2.1 Flared screwed joint, reassembly . . . . . . . . . . . . . . . . . . . . . . . 6  5
6.2.2 Profiled ring joint, reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6  5

6.3 Functional fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 6

6.3.1 Hydraulic fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  6
6.3.2 Level of contaminant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  8
6.3.3 Lubricant analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  8
6.3.4 Storage of lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  8

6.4 Lubricant recommendation . . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 9

6.4.1 Hydraulic fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  11
6.4.2 Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  12
6.4.3 Greases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  13

270100254 IX
 Tableofcontents

Maintenance cards
00−001 Visual checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  17
01−004 Rotor gearbox fullfluidchange . . . . . . . . . . . . . . . 6  19
01−018 Changing the oil in the vacuum pump . . . . . . . . . 6  23
03−001 Changing the hydraulic fluid . . . . . . . . . . . . . . . . . 6  27
03−002 Function checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  33
04−012 Changing the suction filter element . . . . . . . . . . . . 6  35
04−013 Changing the pressure filter element . . . . . . . . . . 6  41
04−014 Changing the ventilation filter element . . . . . . . . . 6  47
04−002 Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  51
04−005 Vacuum meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  55
06−004 Adjusting the pressurerollers . . . . . . . . . . . . . . . . . 6  57
06−029 Water pressure test ontherotor pump . . . . . . . . . 6  61
06−030 Replacing the pump tube . . . . . . . . . . . . . . . . . . . . 6  63
08−010 Adjusting the hopper onrotor pumps . . . . . . . . . . 6  71
10−005 Measuring the wall thickness
(Machines without transfer tube) . . . . . . . . . . . . . . 6  75
12−003 High−pressure water pump . . . . . . . . . . . . . . . . . . . 6  79
20−034 Lubricating the placing boom (TMM24/TMM26) 6  81
21−039 Lubricating the boom pedestal (TR27) . . . . . . . . 6  83
25−001 Replacing the delivery line . . . . . . . . . . . . . . . . . . . 6  85

Index of key words

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

X 270100254
 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 AG
After Sales Department
Max−Eyth−Straße 10
D−72631 Aichtal
Germany
Telephone +49 7127 599−0
Telefax +49 7127 599−520
e−mail: services@pmw.de

or the Branch or Works Agency that looks after you.

Address:

Telephone:

Telefax:

e−mail:

BP01_001_0302EN
 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_9702EN 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 contents of this publication may not be reproduced, even in ex

tract, without our written permission. All technical data, drawings,
etc. are protected by copyright.

© Copyright by

12 BP01_002_9702EN
 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, generally from top to bottom in the sequence shown.

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

See also the maintenance cards:

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

The following special tools are required:

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

Environmental protection
Particular information regarding environmental protection is intro

duced by the icon shown, the words Environmental protection
printed in bold, and a line. The associated text is printed in italics
and ends with another line.

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

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

BP01_003_9508EN 13
 GuidetotheOperatingInstructions

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

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

source of the danger precisely.

Danger of fire
This symbol is used to identify tasks for which there is a particular
danger of fire.

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

Falling items
This symbol is used to identify tasks in which there is a danger of
injury caused by parts falling down.

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

14 BP01_003_9508EN
 GuidetotheOperatingInstructions

Suspended load
This symbol is used to identify tasks in which suspended loads may
fall down.

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

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

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

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

BP01_003_9508EN 15
 2 Safety regulations

This chapter corresponds to the contents of the VDMA brochure

entitled

Safety manual Concrete delivery and placing machines".

Here you will find a summary of the most important safety regula

tions. This chapter is, therefore, particularly suitable as an initial
basic instruction for new operators. Naturally, the various rules are
also repeated once more at the appropriate points in the Operating
Instructions.

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:
 EN 12001, Conveying, spraying and placing machines for
concrete and mortar
 EN 12100, Safety of machinery,
 EN 60204−1, Electrical equipment of machines.
 in the Federal Republic of Germany: ZH 1/573, Code of practice
for concrete pumps and placing booms.

BP03_077_0501EN
 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 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.

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

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

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

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

2.1.6 Truck mixer In this safety manual, truck mixers are vehicles with mixing equip

ment for transporting concrete.

2.1.7 Delivery line systems Delivery line systems are defined 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.

BP03_076_0501EN 21
 Safetyregulations

2.1.8 Machine In this safety manual, concrete delivery and placing machines
referto:
− 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)

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

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

2.1.11 Hoseman Person 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.

2.1.12 Signaller and other Persons instructed by the site management to help the machine
auxiliary personnel operator in his work if the latter is unable to observe all areas of
operation and danger zones. Signallers must be able to indepen

dently 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 communication with the machine operator.

22 BP03_076_0501EN

2.1.13 Truck mixer driver
2.1.14 Authorized inspector
2.1.15 Subject expert
2.1.16 Qualified personnel
2.1.17 After Sales Service
personnel
2.1.18 Maintenance
BP03_076_0501EN
Safetyregulations
Person who supplies the concrete pump with concrete from a
truckmixer. Truck mixer drivers must be instructed by the machine
operator to operate the operating elements on the concrete pump
provided 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
government bodies to carry out this task of inspection. The pre

requisites for becoming an authorized inspector are:
− To have completed a higher education course in engineering
orsimilar.
− To have at least 5years’ professional experience in a relevant
domain, of which at least six months must have involved partici

pation 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
inspection.
− To be able to carry out the tasks impartially.
For the purposes of this safety manual, a subject expert is a
personwho, 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
activity which qualifies them to carry out their roles.
Qualified persons employed by the manufacturer who are
responsible in particular for maintenance of the machine.
Maintenance embraces all measures required for inspection,
servicing and repair of a machine.
23
 Safetyregulations

2.1.19 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_076_0501EN
 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
3 Signaller In the machine operator’s range of vision
pumping
4 Auxiliary personnel As manual delivery system operator
operations)
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
7 Impermissible
beyond 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 Risk of lines bursting, risk of injury by crushing or
13
line systems shearing e.g. by gate valves
14 Structure or area being concreted Example

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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 − The machine operator’s place of work is with the remote control when
machine 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 − The hoseman’s place of work is within the danger zone of the end
hoseman 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 − The truck mixer driver’s place of work is in the danger zone of the
truckmixer 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 Because of their high manoeuvrability, some placing booms can also
workingarea 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
theactivity being carried out and the position of the placing boom.
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. Increased caution is called for and suit

able personal protective equipment is required if a place of work is in
a danger zone. 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 SHUT−DOWN button if an unauthorized person enters
the danger zone.

Support legs and There is a danger of crushing in the swing−out 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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 Safetyregulations

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

End hose The danger zone when pumping is started, during pumping
operations, when removing a blockage and during washing out
procedures 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

between the truck mixer and the hopper and of being sprayed
withconcrete. There is a risk of entanglement with the agitator
ortransfer tube if the grille is not closed.

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 safety−related devices, such as
removable protective devices and EMERGENCY SHUT−DOWN
devices, must be available and fully functional.

The machine is constructed in accordance with the conditions laid

down in the EU Machinery Directive (98/37/EC) and EN12001.
Nevertheless, its use may constitute a risk to life and limb of the user
or of third parties, or cause damage to the machine and to other
property.

The machine is designed exclusively for the delivery and placing of

concrete up to a bulk density of 2,400 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.

Designated use also includes observing the Operating Instructions

and complying with the intervals and conditions for:
− Inspections
− Maintenance

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 Safetyregulations

2.2.1 Inspection intervals After it is used for the first time, the operational safety of the machine
must be checked regularly by a subject expert. The inspection inter

vals depend on the age of the machine.

0 to 5years inclusive: annually

The inspection must be carried out even if one year has not passed
since the last inspection as soon as one of the two criteria
−500operating hours or 20,000m3 pump output − is achieved.

From 5to 10years inclusive: every six months

The inspection must be carried out even if six months have not
passed since the last inspection as soon as one of the two criteria
−250 operating hours or 10,000m3 pump output − is achieved.

More than 10years: quarterly

The inspection must be carried out even if three months have not
passed since the last inspection as soon as one of the two criteria
−125 operating hours or 5,000m3 pump output − is achieved.

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 work

ing order. It must not be tampered with.

The operator is responsible for commissioning the inspection. The

outcome of the inspections must be recorded in the check book and
confirmed by a signature. The check book must always be kept with
the machine and must be produced upon the request of the national
supervisory bodies.

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2.3 Use contrary to Any use of the machine which is not described in section 2.2,
designated use entitled Designated use", or which extends beyond the uses
described 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 this are given below.

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

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
remove 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
control, it is not possible to co−ordinate their movements.

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

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2.3.6 Impermissible The end hose must not be fitted with any extension coupling, spout,
end hose swan neck", outlet shoes or other dangerous outlet fitting or similar
device.

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

delivery pressure greater than 85 bar) through the delivery line of the placing
boom. The delivery line and end hose are only suitable forconcrete
pressures up to 85 bar in their new condition.

2.4 Exclusion of liability The manufacturer’s conditions of delivery apply. We expressly stipu

late that the manufacturer is not liable for any damage caused in the
cases specified in these conditions.

Unless the responsibility of the manufacturer, the warranty will be

invalidated in the following situations, for instance:
− use contrary to designated use
− 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
− adjustment of safety pressures, speeds of movement, power
outputs, 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
orhave received the necessary instruction work on or with the
machine. He must clearly define who is responsible for operation
and maintenance of the machine. He must also ensure that only
persons commissioned 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
theinfluence 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 becovered by
a hair net. Injury may result from hair being caught up in the
machinery or from rings catching on 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 operatethe
machine unless under the constant supervision of anexperienced
person.

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
machine operator operator(including in respect to national road traffic regulations)
andempower him to reject instructions from third parties prejudicial
to safety. The machine operator must be able to reject the site of
operations 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
Instructions theOperating Instructions, in particular the chapter on safety, before
beginning 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 must always be kept to hand at the

siteofuse of the machine (in the tool compartment or container
provided for this purpose).

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

Personnel entrusted with work on the machine must observe all

safety notes and hazard warnings.

Personnel entrusted with work on the machine must be familiar with

the machine itself. You must practice all the operating procedures
described in the Operating Instructions (extending the supports,
operating the placing boom, shifting the placing boom into the
driving position, preparing the vehicle for moving, etc.) under the
supervision of a subject expert until you are certain you can execute
them safely. Ask questions if there is something you have not under

stood. Begin operating the machine only once you are familiar with
the layout 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
inaccordance 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 fire−alarm and fire−fighting
procedures.

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 binding 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
hard hats, protective gloves and safety boots.

Hard hat
A hard hat protects your head against, for instance, falling concrete
or parts of the delivery line in the event of a hose bursting.

Safety boots
Safety boots protect your feet against falling objects and against
penetration by projecting nails.

Ear defenders
Ear defenders protect you against the noise generated by the
machine when you are standing close to it.

Protective gloves
Protective gloves protect your hands against aggressive or chemi

cal substances, as well as against mechanical effects (e.g. impact)
and cutting injuries.

Protective goggles
Protective goggles protect your eyes against injuries from concrete
spatters or other particles.

Safety harness
When working at height, use the climbing aids and working plat

forms provided for reasons of safety or wear a safety harness.
Therelevant national regulations must be complied with.

Face mask and respiratory protector

A face mask and respiratory protector protect you against particles
of building materials which could enter your body through your
respiratory passages (e.g. concrete admixtures).

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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.
Ifnecessary, 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 SHUT−DOWN button. other

wise the machine might execute unintended movements.

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Never put the remote control unit down when the machine is ready
for operation. If this is unavoidable in exceptional cases, you must
press the EMERGENCY SHUT−DOWN button, disconnect the remote
control and lock the remote control unit away (see also
page241).

Never leave the machine when the engine is running or when the
engine could be started by an unauthorized person. If you need
toleave the machine, proceed as follows:
− press the EMERGENCY SHUT−DOWN button,
− 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
forall persons either on the machine or in its vicinity or who are
connected to it (via the remote control, end hose, etc.). A spark can
jump across from a high−voltage line even if you just approach it
andthis 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
decreases from the inside to the outside in this discharge voltage
pattern. If you step within this discharge voltage pattern, you will
bridge different potentials. This will cause a voltage corresponding
tothe 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] 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

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The specified clearances are minimum requirements. You must

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

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

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

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

ifyou wish to estimate correctly the movements of the boom and,
above all, the clearance between the placing boom and obstacles
orhigh−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
placing boom and to lay a separate delivery line, for instance.

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2.9.4 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
machine.
− Have the power switched off.
− Only leave the machine once you are sure that the line you
havetouched or damaged has been de−energized.

Power stations are always equipped with automatic switch−on

devices. If a circuit breaker trips, the short−circuited cable will be
switched back on again after a brief interval. Brief intervals when
thevoltage 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

ifhe is standing outside the discharge voltage pattern.

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2.9.5 Electrostatic charging Faults can be caused in the radio remote control system and
dangerous electrical charging of the machine can occur when
working in the vicinity of transmitters (radio transmitter, etc.).
Personswho bridge the charged parts to the earth are heavily
charged on contact.

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

Secure the earthing cable (at least 16mm2) to an extra pre−
prepared, bright metal point of the machine (e.g. not to a piston rod)
and to a conductive metal rod in the ground (minimum insertion
depth of 1.5m).

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 Safetyregulations
2.10 Stationary machines
2.10.1 Set–up site
2.10.2 Lifting machines
and components
2.10.3 Loading and
transporting
224
Stationary machines are normally used on a construction site
onacontinuous basis over a longer period. For this reason, site
management should prepare the set−up site carefully. The site
management must deliver the necessary documents in good time
inorder to be able to prepare the foundations, base plates or similar
on time.
When selecting the site, remember that the machine must be
dismantled and transported away again at the end of its use
onsite.The ambient conditions may change as construction work
progresses.
Machines which are transported to the site in individual parts or not
under their own power must only be lifted with suitable lifting equip

ment in accordance with the specifications in the Operating Instruc

tions. The lifting gear on the machine must be capable of accepting
the lifting gear and lifting the load. No−one should stand under sus

pended loads. Before work is started, a subject expert must check
that the assembled machine is working properly.
Only use suitable means to load and transport stationary machines.
Ensure that no one could be injured if the machine toppled over or
slipped.
If there are fixtures provided for transport of the machine or its indi

vidual components, only these should be used. The machine or
components must be properly lashed down during transport. The
transport vehicle and machine must be marked to conform with the
road traffic regulations in the country concerned if they are to use the
public highway.
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 Safetyregulations

2.11 Mobile machines

2.11.1 Set–up site It is the machine operator who takes responsibility for setting up
themachine 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 obstacles in the work and travelling areas, the
loadbearing capacity of the supporting ground and any barriers
separating the construction site from public roads.

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 into thesite
where the machine will be set up. If necessary, have the approach
route closed off or secured by signallers. Have any materials or
equipment that hinder your approach removed.

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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,
concrete slabs, etc. may have been washed out underneath.
Neverset the machine up on backfilled ground.

The support area must be enlarged as required. Support blocks

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

Check the stability of the machine regularly during operation.

Interrupt the pumping operation if the machine becomes unstable.
Factors which reduce stability include, for instance:
− modifications to the ground conditions, e.g. 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
clearance to the pits and slopes must be maintained, and such
clearance must be determined in accordance with the nature of
theground. 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
insequence. Intermediate positions are prohibited to guarantee
stability.

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

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

The machine must be made level in all directions. The maximum

permitted deviation from the horizontal is 3_. Greater deviations from
thehorizontal overload the slewing gear for the placing boom and
jeopardize 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.

The front axle is required as the tilting edge on trucks with support
feet mounted directly on the truck superstructure or with support
legs that can be telescoped perpendicular to the vehicle axis. The
stability of the machine is jeopardised if the axle lifts clear of the
ground.

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For this reason, the forward vertical support cylinders must only
beextended until the truck begins to lift itself from the ground. The
tyres must remain firmly seated on the ground. The mass located
infront of the supports when working over the driver’s cab would
increase the tilting moment if the front axle were raised clear of the
ground.

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2.11.5 Driving Observe the following when preparing the truck for driving:
− 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
secured.
− Raised or locked axles must be lowered and released.
− Accessories belonging to the machine must be safely stowed
away and secured.
− The maximum permissible gross weight may not be exceeded.

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

construction 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
passing under overhead cables. The same minimum clearances
apply when driving under high−voltage lines as when working with
the placing boom. Be aware of the height of the truck. Only drive
over arches, bridges or other supporting structures if the load

bearing capacity is adequate.

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

elevated position of the truck’s centre of gravity when travelling on
aslope and on ascending or descending routes. Always adapt
yourtravelling 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.

The mixer drum on truck mixer concrete pumps must only be rotated
at the maximum speed of rotation specified in the Operating Instruc

tions. 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
accordance 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.

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

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Use only appropriate means of transport and lifting equipment of

adequate loadbearing capacity. Lifting equipment, lifting tackle,
support 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.

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2.12 Placing booms

2.12.1 Unfolding the placing Only raise a mobile placing boom from the driving position once
boom themachine has been supported in accordance with the Operating
Instructions. 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

Operating Instructions. The correct sequence depends on the
folding system (roll−and−fold system, Z−fold system, etc.).

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

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

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

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Press the EMERGENCY SHUT−DOWN 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.

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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 operation.
Under certain circumstances it is even possible to overload or cause
damage to the placing boom. We have indicated such impermissible
working areas by the use of warning signs and information plates on
the machine and appropriate notes in the Operating Instructions.

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2.12.2 End hose The end hose must hang freely each time you start pumping, when
you start pumping again after blockages, and during washing out
procedures. No−one 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.

wz0135

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 boom.

Never bend the end hose over. Never attempt to straighten a bent
end hose by increasing the pressure. The end hose must not be sub

merged below the surface of the concrete being delivered, otherwise
the concrete may spray upwards.

The concrete may also spray from the end hose due to the presence
of air in the delivery line. To prevent this from occurring, the hopper
must 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.

BP03_076_0501EN 235
 Safetyregulations

2.12.3 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 to7 (wind speed61km/h=17m/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.

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,
orestimate 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.

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

In addition, such minus temperatures should be considered the

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

236 BP03_076_0501EN

2.13 Delivery line systems
2.13.1 Suitable delivery lines
2.13.2 Securing delivery
lines
BP03_076_0501EN
Safetyregulations
Use only perfect delivery lines, end hoses, couplings, etc. suitable
for the delivery job and manufactured 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.
Delivery lines, delivery hoses, end hoses and couplings must be
securely fastened and secured against spontaneous opening.
wz0065
237
 Safetyregulations

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

wz0045

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. Always try to remove the blockage
by reverse pumping and then restarting forward pumping. If the
blockage is not removed, relieve the pressure on the delivery line
before removing the section of delivery line concerned.

238 BP03_076_0501EN

2.13.4 Opening delivery lines
2.13.5 Clearance to delivery
lines
2.13.6 Fastening delivery
lines
2.13.7 Continuation delivery
lines
BP03_076_0501EN
Safetyregulations
You must not open or tap delivery lines while these are pressurized.
Concrete exiting under pressure can cause injury. Theconcrete
column must be depressurized by reverse pumping before the
delivery line is opened. Never work bending directly over the
coupling.
wz0075
No−one should remain in the vicinity of separate delivery lines during
pumping operations. Cordon off the danger zone. If it is not possible
to place a large enough cordon around the danger zone, the deliv

ery line must be covered by suitable means.
Delivery lines, in particular riser lines which are not laid along
placing booms, must be securely fastened in order to transfer
theforces 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.
A continuation delivery line connected to the placing boom must not
exert a load on the boom.
239
 Safetyregulations

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
possible 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.

240 BP03_076_0501EN
 Safetyregulations

2.14 Pumping operations

2.14.1 Place of work The machine operator’s place of work is with the remote control
whenthe pump is in operation. If you operate the machine using
theremote 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
ofthese 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.

2.14.2 Safety Before switching on the machine, you must make sure that nobody
can be injured by the running machine.

Refrain from any procedures that may impair the stability of the
machine or are prejudicial to safety in any other way.

2.14.3 Remote control unit You must always carry the remote control on your person when
themachine is ready for operation. Only in this way can it be guaran

teed that you can press the EMERGENCY SHUT−DOWN button in
the event of an emergency situation. The EMERGENCY SHUT−DOWN
button may only be unlocked once the cause/emergency has been
remedied (see also page219).

You must carry the remote control unit in such a way that no control
element is actuated unintentionally.

During breaks in pumping, interruptions, maintenance work or your

absence from the machine, you must secure the machine against
inadvertently rolling away and to prevent unauthorized use. Press the
EMERGENCY SHUT−DOWN button on the remote control and lock
the remote control away.

BP03_076_0501EN 241
 Safetyregulations
2.14.4 Moving machine
components
2.14.5 Constant observation
of the machine
2.14.6 Truck mixer
242
Keep all access covers, maintenance flaps, guards, etc. closed
andlocked during operation. This also applies to the grille, water
box cover, and covers on cylinders, for example. There is otherwise
a risk of injury from moving machine components.
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
isrunning 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
orfaults while it is in use. In the event of faults or malfunctions that
impair 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 delivering the concrete to you. 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.
BP03_076_0501EN
 Safetyregulations

2.15 Cleaning

2.15.1 General You must drain the delivery line, pump and hopper completely.
Concrete 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
orthe 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.

wz0155

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

Never spray remote control units or control cabinets with barrier

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

BP03_076_0501EN 243
 Safetyregulations

2.15.2 Cleaning agents Take care when using aggressive cleaning agents. Wear protective
clothing.

wz0145

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

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.

244 BP03_076_0501EN
 Safetyregulations

2.15.4 Cleaning with Compressed air should only be used for cleaning purposes in
compressed air accordance with the manufacturer’s instructions and under the
supervision of a subject expert.

2.15.5 Protection against Water spraying on the machine from random directions has no
water damaging 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
cabinets 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 page218).

Look out for leaks, loose connections, chafe marks and damage
during 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_076_0501EN 245
 Safetyregulations

2.16 Requirements for In the capacity of operator, it is your responsibility to provide all the
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
specifications for the replacement of parts and equipment. These
activities 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.
− Fix a warning plate to the main switch.

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 ladders 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
andice.

246 BP03_076_0501EN
 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
adequate 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,

ofany 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,

hydraulic fluid radiator, etc.).

Ensure that all functional fluids, consumables and replaced parts are
disposed of safely and with minimum environmental impact.

BP03_076_0501EN 247
 Safetyregulations

2.17 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 and welding machine directly to the
component that is to be welded. The welding current must not flow
through hinges, cylinders, etc. Significant damage may be caused
by current bridging gaps.

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, flame−cutting 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.

248 BP03_076_0501EN
 Safetyregulations

2.18 Working on the Only carry out maintenance and repair work on the placing boom
placing boom ifthe 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 ifthe delivery
line is replaced when the placing boom is unfolded.

Following substantial changes, placing booms must be inspected by

an authorized inspector before recommissioning.

2.19 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
personnel. Seals must only be removed by the manufacturer’s
AfterSales Service personnel. Modifications to the machine ratings
(for example, increasing pressures, modifying speeds, etc.) are not
permitted.

BP03_076_0501EN 249
 Safetyregulations

2.20 Protective and safety Any safety devices removed for maintenance purposes must be
equipment refitted and checked immediately upon completion of this work.

All equipment required for safety and accident prevention (warning

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

Keep all warning signs and information plates on the machine

complete and in a perfectly legible condition.

It is your responsibility as operator to ensure that any warning

signsand information plates that have been damaged or rendered
illegible are replaced without delay.

250 BP03_076_0501EN
 Safetyregulations

2.21 Electrical power

2.21.1 General Work on electrical systems or operating equipment must only be

carried out by qualified personnel. For further information on ma

chines operated on the site power supply, see also section2.21.3.

The power supply to machine components on which maintenance

work is to be carried out must be isolated, if provided for in
theregulations. Before starting any work, you must check the
de−energized parts for the presence of power and earth or
short−circuit them in addition to insulating adjacent live parts and
elements. Disconnect the negative lead from the battery before
starting any work on the electrical system. When reconnecting,
connect the positive terminal first, and then the negative terminal.

Before starting work on high−voltage assemblies and after cutting

the power supply, you must connect the supply cable to earth and
short−circuit the components such as capacitors with a rod−type
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
ared−and−white safety chain and a warning plate. Use insulated
tools only.

BP03_076_0501EN 251
 Safetyregulations
2.21.2 Electrical components
2.21.3 Power at the
construction site
252
As a standard finish, the control cabinet, motor and control elements
are protected in accordance with degree of protection IP54 as speci

fied in IEC60204 part1. IP54 means protection against:
− contact with live parts
− contact with internal moving parts
− hazardous dust accumulations
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.
The power on the construction site must be supplied from a special
feed point (construction site power distribution point).
Only qualified personnel may work on electrical systems with
anoperating 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
result 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.
BP03_076_0501EN
 Safetyregulations

2.22 Hydraulic systems

2.22.1 General Work on hydraulic systems must only be carried out by qualified
personnel.

Always wear your personal protective equipment when carrying

outwork on the hydraulic system. Escaping fluid is toxic and can
penetrate the skin.

Parts of the system and pressure lines which are to be opened

(hydraulic, pneumatic, and delivery lines) must be depressurized
according to assembly descriptions before repair work is carried out.

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 forbidden.

Route and install the hydraulic lines in accordance with the current
rules of engineering. Ensure that connections are not interchanged.
The fittings, lengths and quality of the hoses must comply with the
technical requirements.

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.

Damaged hydraulic lines must be replaced rather than repaired. You

must replace damaged or saturated hydraulic hoses immediately.
Splashed hydraulic fluid may cause injury and fire.

2.22.2 Replacing hydraulic During the repeat inspections, a subject expert must check the
hoses hydraulic hoses for external damage. The inspection must be
recorded in the check book. The operator must have hydraulic lines
replaced if they show signs of external damage.

BP03_076_0501EN 253
 Safetyregulations

2.23 Noise emissions The place of work in normal operation is with the remote control. For
this reason, it is not possible to lay down a specific 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

machine.

As 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. The
high sound level can cause permanent hearing damage.

2.24 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.

254 BP03_076_0501EN
 Safetyregulations

2.25 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.

wz0145

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
perspiration). Admixtures are toxic and caustic.

BP03_076_0501EN 255
 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

(riskof 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.

wz0185

256 BP03_076_0501EN
 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 Summary Below you will find an overview of the most important components;
these will then be described on the following pages.

Left truck side

1 2 3 4 5 6 7 8 9 10 11

MP02_323_0411EN 1

No. 0 Component Page

1 Documentation accompanying the machine
2 Radio and/or cable remote control 355
3 Boom rating plate 39
4 Left support control block 372
5 Truck mixer water pump (optional), see documentation for truck mixer
6 Pressurised water system (optional) 381
7 High−pressure water pump (optional) 382
8 Control panel on the outside of the machine 353
9 Rotor pump 315
10 Machine rating plate 38
Vacuum pressure gauge 319
11
Rotor pump ventilation cock 319

MP02_323_0411EN 31
 Generaltechnicaldescription

Right truck side

1 2 3 4 5 6 7 8 9 10

MP02_323_0411EN 2

No. 0 Component Page

1 End hose (on the boom tip) 378
2 Agitator safety cutout 368
3 Chute 389
4 Vibrator (on the grille) 385
Pump control system 370
Main hydraulic pump emergency control lever 370
5
Agitator/water pump emergency manual operation 370
Agitator direction of rotation emergency manual operation 370
6 Control panel 350
7 Hydraulic fluid radiator 386
8 Right support control block 372
Control cabinet (in the stowage compartment) 321
9 Diagnostics socket
Ergonic Graphic Display 323
10 Boom control block 375

32 MP02_323_0411EN
 Generaltechnicaldescription

3.2 Safety equipment This illustration shows examples of safety equipment which may be
fitted on themachine. The mounting location may differ on different
machine models.

Left–hand side of truck, PUMI general

1 2 3 4 5 6 7

MP02_254_0309EN 1

No. 0 Safety equipment

1 EMERGENCY SHUT−DOWN button / STOP button on the remote control
2 Cover over the universally jointed shaft of the mixer drive
3 Snaplock on the support leg
4 Two−hand control device for the support legs
5 EMERGENCY SHUT−DOWN button
6 Safety valve for compressed air water tank
7 Retaining rope on the end hose

MP02_254_0309EN 33
 Generaltechnicaldescription

Right–hand side of truck, PUMI general

1 2 3 4

MP02_254_0309EN 2

No. 0 Safety equipment

1 Mechanical grille securing device
Toggle switch with padlock for Local control − 0 − Remote control
2 EMERGENCY SHUT−DOWN button
Two−hand control device for the support legs
3 Cover over the boom functions control block
4 Snaplock on the support leg

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

Check the safety equipment as described in the Operating Instructions.

34 MP02_254_0309EN
 Generaltechnicaldescription

PUMI Q

1
4

MP02_254_0309EN 3

No. 0 Safety equipment

1 Retainer for inspection cover on the rotor housing
2 Securing cotter pins on the delivery line couplings
3 Grille on the hopper
4 Agitator safety cutout

MP02_254_0309EN 35
 Generaltechnicaldescription

PUMI CS

1 3

MP02_254_0309EN 4

No. 0 Safety equipment

1 Cover over the switch cylinders
2 Spray guard
3 Grille on the hopper
4 Agitator safety cutout
5 Retaining hook for cleaning cap gate

36 MP02_254_0309EN
 Generaltechnicaldescription

3.3 Technical data You will find the technical data and setting values for your machine in
the 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 A certificate of compliance with the EMC protection requirements

compatibility (EMC)
has been issued in accordance with Article 10 paragraph 2 of Coun

cil Directive 89/336/EEC on the harmonization of the regulations in
member states concerning electromagnetic compatibility, implem

ented in Germany by the law concerning the electromagnetic com

patibility of equipment, dated 9November1992 (EMVG, section 5.2).

Customer: PutzmeisterAG
Max−Eyth−Strasse10
72631Aichtal, Germany
To be inspected: Concrete pump control with ZMS−K
(central modular control cabinet)
Test location: EMCtech GmbH, Waiblingen,
Absorberhalle
Test report no.: P011026
Date of testing: 14 February 2001

Inspection type Individual tests Basic standard Range Requirement Result

Emission − radiated Radio interference field intensity EN 13309:2000 30 − 1000 MHz Broadband − A.1 passed
interference (SA) Narrow band A.3
EN 13309:2000

Immunity − interfer
RF field, AM − modulated ISO 11451−2 20 − 1000 MHz 30 V/m Peak = passed
ence resistance (SF) 17 V/m + AM
EN 13309:2000 80%/1kHz

Vehicle voltage pulses ISO 7637−2 1, 2, 3a, 3b Degree of passed

on cable remote control severity I
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. P011026. The inspections carried out with regard to
radiated interference and interference resistance were passed.

BP02_002_0201EN 37
 Generaltechnicaldescription

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

1 PUMI 26.67 Q
2 270100254
3 2005 7 32000
4 260 8 25
5 80 9 1200
6

BP02_002_0201EN 1

No. 0 Designation
1 Model (machine model)
2 Machine no. (machine number)
3 Year of manufacture
4 Maximum hydraulic pressure [bar]
(maximum fluid pressure in the hydraulic system)
5 Maximum permitted speed [km/h]
(maximum permitted speed of the truck)
6 Acceptance inspection
7 Permitted gross weight [kg]
8 Maximum concrete pressure [bar]
9 Maximum rpm (maximum engine speed)

38 BP02_002_0201EN
 Generaltechnicaldescription

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

1 TMM 26
2 170204029
3 2005
4 420 607
5 22
6 26
7 108 x 4,0
8 3
9 350
10 85

BP02_002_0201EN 2

No. 0 Designation
1 Boom model
2 Boom no.
3 Year of manufacture
4 AP−AN (arm assembly part number)
5 Horizontal reach max. (maximum net reach)
6 Maximum vertical reach
7 Pipe (maximum permitted pipe diameter and wall
thickness of the delivery line) [mm]
8 Maximum end hose
9 Maximum hydraulic fluid pressure
10 Maximum concrete delivery pressure

BP02_002_0201EN 39
 Generaltechnicaldescription

3.3.4 Sound pressure level The sound pressure level produced by the machine is given below in
accordance with Directive 98/37/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_0201EN 1

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

310 BP21_359_0201EN
 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.
Tomeasure 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

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

BP21_359_0201EN 311
 Generaltechnicaldescription

3.3.6 Reaches The TMM26 has the reaches listed below.

262°

180° 3

120°

360_

1
5

MP02_073_9903EN 1

1 Horizontal reach from middle of slewing unit 21.8m

2 Horizontal reach from front edge of truck 19.4m
3 Vertical reach 25.6m
4 Unfolding height 7.6m
5 Depth of reach with 3m end hose 13.6m

312 MP02_073_9903EN
 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 Hydraulic system The hydraulic drive for the rotor pump comprises three hydraulic
circuits. The main circuit for the rotor drive (delivery unit) is a closed
circuit.

The variable−displacement pump delivers the fluid to the hydraulic

motor for the delivery unit and returns the depressurized fluid from
the motor. A certain amount of leakage from the flushing valve in the
hydraulic unit is returned to the hydraulic fluid reservoir. The same
volume of fluid is simultaneously extracted from the hydraulic fluid
reservoir by the feed pump and supplied to the circuit again.

The servo adjuster valve on the variable−displacement pump

switches:
− Depressurized fluid circulation − Rotor STOP
− Rotor FORWARDS
− Rotor BACKWARDS

As the speed of the truck engine increases, the speed of the vari

able−displacement pump and thus the quantity of fluid it delivers
also increases. This means that the speed of the rotor also increases.

Should the hydraulic pressure increase because stiff fresh concrete

is being pumped, for instance, the variable−displacement pump will
automatically reduce its output. The quantity of fluid delivered thus
becomes less, the rotor turns more slowly.

The truck engine’s speed is only adjusted electrically by means of

Electronic Diesel Control (EDC) on engines complying with the
EURO 3 standard and newer.

A constant−displacement pump is fitted as a drive pump for supply

ing the fluid to the placing boom and the cleaning equipment. There
is an additional pump for the fluid supply to the agitator. These two
drive pumps run in an open fluid circuit. This means that the quantity
of fluid delivered, for the placing boom, for instance, is taken directly
from and flows back to the reservoir through the solenoid−operated
valves and the hydraulic cylinders.

314 MP02_006_0308EN
 Generaltechnicaldescription

3.4.6 Pump Putzmeister pumps are driven hydraulically by diesel engines. The
output can be infinitely adjusted to any value required. The delivery
unit comprises the rotor housing (3) and the rotor (5) rotating around
a central axis with the two pressure rollers (2). The rotor is driven by
a variable hydraulic pump, the hydraulic motor and a planetary gear

ing. The pressure rollers run freely.

Inside the rotor housing there is a special pump tube (1) which is
squeezed together by the pressure rollers rolling over it. This pushes
the material in the pump tube ahead of the pressure roller towards
the rotor housing outlet and into the delivery line (4).

1 2 3 4

2 5
MP02_006_0308EN 1

No. 0 Designation
1 Pump tube
2 Pressure roller
3 Rotor housing
4 Delivery line
5 Rotor

MP02_006_0308EN 315
 Generaltechnicaldescription

Note
There is an underpressure in the rotor housing to ensure that the
concrete delivery hose behind the pressure roller rapidly returns
toits original cross section. An underpressure is generated in the
delivery hose as a result of the delivery hose rapidly returning to its
original cross section. This causes the concrete to be sucked in from
the agitator hopper.

The material is sucked back, or reversed, by the rotor rotating in the

other direction. The material sucked back from the delivery line is
thus delivered into the hopper.

316 MP02_006_0308EN
 Generaltechnicaldescription

3.4.7 Vacuum system The vacuum system is only driven hydraulically from rotor pump
model R 62 upwards.

1 2 3

MP02_006_0308EN 2

No. 0 Designation
1 Rotor housing
2 Hydraulic motor
3 Vacuum pump

You can find all the technical data for the vacuum pump on its rating
plate.

Note
Check the oil level in the vacuum pump before each use. Top up with
oil with a viscosity grade of SAE30 or SAE 10 as required.

Maintenance card: Changing the oil in the vacuum pump

Place the vacuum pump on a level surface.

Check the direction of rotation of the hydraulic motor (see direction
of rotation arrow on the hydraulic motor). If the direction of rotation is
incorrect, have the hydraulic ports swapped by qualified personnel.

MP02_006_0308EN 317
 Generaltechnicaldescription

Vacuum pump
1 2

7 6 5 4 3

8 9 10 11

12
MP02_006_0308EN 3

No. 0 Designation
1 Hydraulic motor
2 Oil filler plug
3 Vacuum pump
4 Vacuum pump rating plate
5 Oil inspection glass
6 Oil drain plug
7 Oil filter (not on model 0012, 0016)
8 Filter elements
9 Oil trap
10 Exhaust side
11 Intake port with integrated check valve
12 Oil return line

318 MP02_006_0308EN
 Generaltechnicaldescription

3.4.8 Ventilation cock

1 2

40600101

No 0 Designation
1 Vacuum meter
2 Ventilation cock

Note
A vacuum is generated in the rotor housing if the engine is running
and the power take−off engaged with the ventilation cock(2) closed.
You can read the value of the vacuum generated on the vacuum
meter(1).

MP02_031_9912EN 319
 Generaltechnicaldescription

3.5 Electrical control The electrical control devices and operating elements on this ma

devices chine are described on the following pages. The overview 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
− Control panel
− Switch box
− Centralized lubrication system
− Cable remote control
− Radio remote control
− EMERGENCY SHUT−DOWN button

Note
Further control devices and components are described in the
Hydraulic control devices" (from page 369) and Other
components" (from page 377) sections.

320 MP02_106_9909EN
 Generaltechnicaldescription

3.5.1 Control cabinet You can determine some of the machine’s operating statuses and
functions from the Ergonic Graphic Display on the control cabinet.
Some of the control and operating elements illustrated below may
not be present in the equipment of your machine.

2 3

1 6 5

MP02_259_0411EN 1

Operating/
No. 0
control element
1 Female connector
2 Locally latched toggle
switch (optional)
3 Ergonic Graphic Display
4 Locally latched toggle
switch
5 Female connector
6 Toggle switch
Belongs
Meaning/Function
with no.:
Connection for remote control
Support leg warning lights On−Off
Displaying and setting operating states
Local control − 0 − Remote control
Diagnosis
Working light On−Off

MP02_259_0411EN 321
 Generaltechnicaldescription

Special features of the control cabinet

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 SHUT−DOWN circuit is activated automatically

remote control when you switch over from local to remote control. You must operate
the horn to deactivate the EMERGENCY SHUT−DOWN circuit.

MP02_259_0411EN 2

Local control − 0 − Remote control toggle switch

Diagnostics socket To capture data from the machine, a diagnostics unit can be con

nected to the diagnostics socket by authorised and qualified person

nel.

Locking The control cabinet may be found in a stowage compartment. You

must always lock this stowage compartment to prevent any unautho

rised person switching the control system over.

322 MP02_259_0411EN
 Generaltechnicaldescription

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

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.

EGD and operating

elements

2
1

BP21_653_0502EN 1

Operating/
No. 0 Function / meaning
control element
Ergonic Graphic Display Menu−driven displays and adjustable functions are
1
(EGD) shown in the EGD.
2 Push−button Function buttons F1, F2, F3 for navigating
3 Rotary push−button Function button F4 for selecting and setting

BP21_653_0502EN 323
 Generaltechnicaldescription

Using the Ergonic Graphic Display

You can navigate in the menus using function buttons F1, F2 and F3.
Use function button F4 to set selectable functions as follows:
− Turn F4 to select a function.

The function is displayed in inverse video.
− Then press F4 to activate the selected function.

The function flashes.
− Now turn F4 to change the settings.
− Press F4 to store the changed setting.

The function is displayed in inverse video.

324 BP21_653_0502EN
 Generaltechnicaldescription

EGD symbols The following shows the Ergonic Graphic Display symbols.

Note
If the symbol is displayed in inverse video (see the following
example for the brightness" function), this means that the symbol
has been selected or that the associated function is switched on. If a
symbol flashes, the sensors for the associated function are defective.

1 2 3 4 5 6 7

8 9 10 11 12

BP21_667_0506EN 1

No. 0 Designation
1 Jump back one menu level
2 Information
3 Service
4 Brightness
5 Contrast
6 Fault
7 Hydraulic fluid
8 Engine speed
9 Preset engine speed (1, 2, 3)
10 Hydraulic fluid high pressure
11 Hydraulic fluid temperature
12 Wall thickness of the delivery line

BP21_667_0506EN 325
 Generaltechnicaldescription

1 2 3 4 5 6 7

8 9 10 11 12 13 14

BP21_667_0506EN 2

No. 0 Designation
1 EOC function Off
2 EOC function On
3 EOC function can be selected on the radio remote control
4 Magnetic switches
5 Hydraulic fluid overheating
6 EMERGENCY SHUT−DOWN
7 High−pressure water pump dry running cut−out
8 Transfer tube
9 Hopper fill−level sensor
10 Pump On
11 Reverse pumping
12 Pump Off
13 Agitator safety cutout
14 Hydraulic fluid pressure at the agitator motor

326 BP21_667_0506EN
 Generaltechnicaldescription

1 2 3 4 5 6 7

8 9 10 11 12 13 14

15 16 17
BP21_667_0506EN 3

No. 0 Designation
1 Mixer speed sensor
2 Hydraulic fluid radiator
3 Hydraulic fluid radiator in automatic operation
4 Hydraulic fluid radiator On
5 Squeeze valve Off
6 Squeeze valve On
7 Engine oil temperature
8 Engine oil pressure
9 Switching to piston side feed
10 Switching to rod side feed
11 Boom fault
12 Oil low pre−warning
13 Coolant overheating
14 Rotor speed sensor
15 Battery (charge monitor)
16 Transposable units (bar, °C) / (psi, °F)
17 Output current monitor

BP21_667_0506EN 327
 Generaltechnicaldescription

Menu structure The password free part of the menu structure is illustrated on the fol

lowing pages (example illustration). When the machine is set up,
HOME" is always displayed as the start screen.

1 2

3 5

4 6

MP02_287_0502EN 1

No. 0 Display Function / meaning See page

1 HOME Data display 329
Press F1 in HOME to display the Pump status"
2 Pump status 332
menu.
Press F2 in HOME to display the Pump settings"
3 Pump settings 339
menu.
Press F3 in HOME to display the Maintenance"
4 Maintenance 342
menu.
Press F2 in the Maintenance" menu to display the
5 Service 343
Service" menu.
Press F3 in the Maintenance" menu to display the
6 Info 344
Info" menu.

328 MP02_287_0502EN
 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 = Maintenance" menu
− F4 = no function

3 4

5
2
6
7
8
1
9

10
11

18 17 16 15 14 13 12
BP21_655_0502EN 2

No. 0 Display Function / meaning

1 Temperature display, digital
Temperature display, ana

2
logue
3 Operating hours meter
4 Pump function
5 Engine speed, digital
6 Engine speed, analogue
The temperature of the hydraulic fluid is displayed in
numbers.
The temperature of the hydraulic fluid is displayed
graphically.
The machine operating hours are displayed.
The pump off", pump on" and reverse pumping"
functions are displayed.
The current engine speed is displayed in numbers.
The current engine speed is displayed graphically.
Thescale for the graphic display ranges from 0 to the
selected maximum engine speed (see Pump settings"
menu).
→

BP21_655_0502EN 329
 Generaltechnicaldescription

3 4

5
2
6
7
8
1
9

10
11

18 17 16 15 14 13 12
BP21_655_0502EN 4

Continued
No. Display Function / meaning
The set engine speed is displayed
7 Maximum engine speed
(seePumpsettings" menu).
The set pump output limit is displayed
8 Pump output
(seePumpsettings" menu).
The high pressure of the hydraulic fluid is displayed
9 High pressure, digital
innumbers.
The high pressure of the hydraulic fluid is displayed
graphically. The scale for the graphic display ranges
10 High pressure, analogue
from 0 to the selected maximum high pressure
(seePump settings" menu).
The set high pressure limit is displayed
11 Maximum high pressure
(seePumpsettings" menu).
12 EOC EOC function switched on or off.
Hopper fill−level sensor
13 Inverse display if the hopper is full.
(optional)
→

330 BP21_655_0502EN
 Generaltechnicaldescription

3 4

5
2
6
7
8
1
9

10
11

18 17 16 15 14 13 12
BP21_655_0502EN 6

Continued
No. Display Function / meaning
Inverse display if the hydraulic fluid radiator is
14 Hydraulic fluid radiator
switched on.
EMERGENCY SHUT− Symbol flashes if an EMERGENCY SHUT−DOWN
15
DOWN button is operated.
Symbol flashes if the temperature of the hydraulic fluid
16 Hydraulic fluid overheating
has exceeded 85°C.
Symbol flashes if a fault has occurred (see also Pump
17 Fault
status" menu).
Piston pump: the current number of strokes is
Number of strokes or
18 displayed
rotorspeed, digital
Rotor pump: the current rotor speed is displayed

BP21_655_0502EN 331
 Generaltechnicaldescription

“Pump status” menu In this menu you can see the various machine operating states.
Function buttons F2 and F3 have no function. Use F1 to go back to
the HOME" menu and use F4 to switch the sensors on or off.

Note
If there is a fault on the machine while the concrete pump is switched
on, the EGD automatically switches to this menu. To quit the menu,
you must first switch off the concrete pump.

2 3
1

21 6
20
7
19
8
18
9
17

16 15 14 13 12 11 10

MP02_285_0507EN 2

No. 0 Display Function / meaning

1 Main hydraulic pump The slewing motion is displayed graphically.
2 Rotor pump The rotation of the rotor is displayed graphically.
3 Navigation symbol Press F1 to display the HOME" menu.
4 Delivery direction An arrow indicates the direction of delivery.
Duration of one rotor
5 The duration of one rotor revolution is displayed.
revolution
→

332 MP02_285_0507EN
 Generaltechnicaldescription

2 3
1

21 6
20
7
19
8
18
9
17

16 15 14 13 12 11 10

MP02_285_0507EN 4

Continued
No. Display Function / meaning
6 Rotor speed The current rotor speed is displayed.
Mixer drum speed of rota
The current speed of rotation of the mixer drum is dis

7
tion played.
Symbol flashes if the mixer speed sensor is defective.
8 Mixer speed sensor Switching off the mixer speed sensor will deactivate
the mixer regulation and CSD functions.
The symbol flashes if there is a fault on a configured
9 Output current monitor output. The number of the defective output is also dis

played.
10 Rotor speed sensor Symbol flashes if the rotor speed sensor is defective.
11 Fill−level sensor Symbol flashes if the hopper is full.
12 Agitator safety cutout Symbol flashes if the agitator safety cutout is activated.
→

MP02_285_0507EN 333
 Generaltechnicaldescription

2 3
1

21 6
20
7
19
8
18
9
17

16 15 14 13 12 11 10

MP02_285_0507EN 6

Continued
No. Display Function / meaning
Symbol flashes if the temperature sensor in the flush

13 Hydraulic fluid overheating ing fluid line of the main hydraulic pump measures
85°C or is defective.
Symbol is displayed inverse if the high−pressure water
pump is switched on.
High−pressure water pump
14 Symbol flashes if the water level falls below the level of
dry running cut−out
the fill−level sensor while the high−pressure water
pump is switched on.
Symbol flashes if there is no speed of rotation signal
15 Engine speed (e.g. engine off, engine speed sensor on the truck is
defective).
EMERGENCY SHUT− Symbol flashes if an EMERGENCY SHUT−DOWN but

16
DOWN ton is operated.
17 Fault Symbol flashes if a fault has occurred.
Symbol flashes if the pressure sensor on the main hy

18 High pressure
draulic pump is defective.
19 Engine speed The current engine speed is displayed.
20 High pressure The hydraulic fluid high pressure is indicated.
The current that controls the swashplate valve is dis

21 Ammeter
played.

334 MP02_285_0507EN
 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 ... selected defective switched off

switched on
Symbol inverse flashing struck through

These sensors can be switched off:

− High pressure
− Engine speed
− Hydraulic fluid overheating
− Fill−level sensor
− Mixer speed sensor
− Rotor speed sensor
− Output current monitor

Note
Switch the sensors on and off using function button F4.
Possible causes for missing sensor signals are: defects, contamina

tion, break of contact, etc.
As soon as no current is supplied to the control cabinet (e.g. ignition
off, power take−off off), the settings are reset to the factory settings.

MP02_285_0507EN 335
 Generaltechnicaldescription

Switch sensors on / off Switch the sensors on and off as follows, using function button F4.

" Turn F4 to select a sensor.

A black square will appear in the top left corner of the sym

bol.

" Press F4 to confirm the selection.

A black square will flash in the top left corner of the symbol.

" Turn F4 to switch the sensor on or off.

A broken black square will flash in the top left corner of the
symbol.

" Press F4 to confirm.

The symbol is displayed struck through.

High pressure The power of the hydraulic system is regulated electronically. The
high pressure" symbol flashes if the pressure signal for the system
is absent. You can switch off the sensor (as described above). This
automatically limits the output to 50%. The display jumps automati

cally to the Pump settings" menu. There the settings are automati

cally set to the factory settings.

Engine speed If the engine speed" symbol is flashing, the speed of rotation signal
from the engine is absent. You can switch off the sensor (as de

scribed above). This automatically switches off EOC operation. The
engine speed is limited to the value preset in the Pump settings"
menu (rpm1/2/3). The engine speed must be adjusted manually.

336 MP02_285_0507EN
 Generaltechnicaldescription

Hydraulic fluid over
If the hydraulic fluid overheating" symbol flashes, the temperature of
heating the hydraulic fluid has exceeded 85°C. This reduces the output
gradually to 10%. If the sensor is defective, you can switch it off (as
described above). This reduces the output to 50% and the hydraulic
fluid radiator fans are switched on if the engine is running.

Output current monitor Some of the EPS control outputs are assigned to functions (such as
pump control system, transfer tube valve and mixer control unit). The
allocation of the output functions can be found in the accompanying
electrical circuit diagram. These output functions also have current
monitoring. The instantaneous output current value is compared to a
pre−set value. If the output current exceeds the pre−set value due to
a fault (eg short−circuit), the associated output is switched off and a
fault message is forwarded to the EGD. The output current monitor"
symbol and the number of the defective output flash in the EGD.

Emergency operation is possible if the output current monitor" func

tion in the EGD is switched off. In standby mode the defective output
is switched off and restricted to a preset maximum value.

The output current monitor" function can be switched on again once

the fault has been remedied by a Putzmeister service technician.

MP02_285_0507EN 337
 Generaltechnicaldescription

Dry running cut−out The high−pressure water pump can only be switched on if the water
tank is full enough.

The high−pressure water pump dry running cut−out prevents the

high−pressure water pump running dry if the water tank is empty.

If the water level drops below the level of the fill−level sensor, the
high−pressure water pump dry running cut−out" symbol flashes and
the high−pressure water pump switches itself off or cannot be
switched on. This ensures that the high−pressure water pump is not
damaged by inadvertently being allowed to run dry.

The dry running cut−out can be overridden using manual emergency

operation (see high−pressure water pump") if the fill−level sensor
fails.

338 MP02_285_0507EN
 Generaltechnicaldescription

“Pump settings” menu In this menu you can set the performance ratings for the machine.
Function buttons F2 and F3 have no function. Press F1 to return to
the HOME" menu. Use F4 to adjust settings.

Note
The following settings are programmed at the works:
 High pressure = 100%
 Pump output = 100%
 EOCI (the default setting EOCI"=EOCON" can be changed
by service engineers).
 Hydraulic fluid radiator AUTO
 Squeeze valve Off

The hydraulic fluid radiator is set to AUTO" at the works. If the main
hydraulic pump flushing fluid reaches a temperature of 65_C on the
first temperature sensor or 70_C on the second temperature sensor
the fan on the hydraulic fluid radiator will come on.

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).

As soon as no current is supplied to the control cabinet (e.g. ignition

off, power take−off off), the settings are reset to the factory settings.

If you reduce the pump output, you will use less fuel and reduce the
wear on machine components.

MP02_335_0506EN 339
 Generaltechnicaldescription

1 2 3

5
11

10 9 8 7 6

MP02_335_0506EN 2

No. 0 Display Function / meaning

1 High pressure, analogue
2 High pressure, digital
3 Navigation symbol
4 Pump output, analogue
5 Pump output, digital
6 Selectable units
The set hydraulic fluid high−pressure limit is displayed
graphically and can be set to between 10% − 100%
using F4.
The set hydraulic fluid high−pressure limit is displayed
in numbers.
Press F1 to display the HOME" menu.
The set pump output limit is displayed graphically and
can be set to between 20% − 100% using F4.
The set pump output limit is displayed in numbers.
Select either the international (bar, °C) or the Eng

lish(psi, °F) system of units.
→

340 MP02_335_0506EN
 Generaltechnicaldescription

1 2 3

5
11

10 9 8 7 6

MP02_335_0506EN 4

Continued
No. Display Function / meaning
7 Squeeze valve (optional) Use F4 to switch the squeeze valve on/off (I/0).
The operation mode for the hydraulic fluid radiator can
8 Hydraulic fluid radiator
be switched using F4 (AUTO / ON).
One of the maximum engine speeds specified at the
works (see test reading) can be set using F4.
9 Engine speed
This function is deactivated when the EOC function is
switched on.
The EOC function can be switched on / off (I/0) using
10 EOC
F4
11 Engine speed The currently set maximum engine speed is displayed.

MP02_335_0506EN 341
 Generaltechnicaldescription

“Maintenance” menu In this menu you can see the maintenance indicators for the
machine. The function buttons have the following functions:
− F1 = HOME" menu
− F2 = Service" menu
− F3 = Info" menu
− F4 = no function

BP21_660_0402EN 2

No. 0 Display Function / meaning

1 Wall thickness
2 Navigation symbol
3 Navigation symbol
4 Navigation symbol
5 Space for further displays
The wall thickness at the measuring point of the
delivery line is displayed.
Press F1 to display the HOME" menu.
Press F2 to display the Service" menu.
Press F3 to display the Info" menu.

342 BP21_660_0402EN
 Generaltechnicaldescription

“Service” menu From this menu you can navigate to the password−protected service
area of the EGD. Function buttons F2 and F3 have no function. Press
F1 to return to the HOME" menu. Use F4 to set the brightness and
contrast on the EGD and to input a password.

BP21_665_0402EN 2

No. 0 Display Function / meaning

1 Navigation symbol Press F1 to display the HOME" menu.
2 Brightness The brightness can be adjusted.
3 Contrast The contrast can be adjusted.
4 Input field The password for the service area can be entered.
5 Selecting the letters Select the letters to make a password.

It is necessary to enter a password in order to unprotect the

Putzmeister Service displays. Access is password−protected
andpermitted only to Putzmeister Service engineers.

BP21_665_0402EN 343
 Generaltechnicaldescription

“Info” menu This menu lists the control systems software versions. Press F1 to
return to the HOME" menu. Function buttons F2, F3 and F4 have no
function.

BP21_661_0402EN 2

No. 0 Display Function / meaning

1 Navigation symbol
2 Software versions
3 Machine number
Press F1 to display the HOME" menu.
The software versions for the control systems are
displayed.
The machine number is displayed.

344 BP21_661_0402EN
 Generaltechnicaldescription

3.5.3 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. high−density concrete).

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

When the EOC function is switched off, the maximum engine speed
specified by the works that you have selected is activated.

“Pump settings”
menu

1 2
BP21_672_0503EN 2

No. 0 Display Function / meaning

Ergonic Output Control The EOC function can be switched on / off using F4
1
(EOC) (I/0) or can be switched on the radio remote control.
One of the maximum engine speeds specified at the
works (see test reading) can be set using F4.
2 Engine speed
This function is deactivated when the EOC function is
switched on.

BP21_672_0503EN 345
 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 toggle switch to the radio remote control" position.

Engaging the power The engine speed remains at 850rpm after the power take−off is
take−off engaged.

Boom or support leg The engine speed is increased to 1350rpm as soon as you operate
function a boom or support leg function with the concrete pump switched off.

Water pump and other As previously described, the engine speed is reduced after
auxiliary units 10seconds when the concrete pump is switched off. You must
increase the engine speed manually in order to operate the water
pump or the other auxiliary units. If you have manually increased the
engine speed once, this remains increased until you move the boom
again or switch on the concrete pump. The 10second countdown
then begins again.

346 BP21_672_0503EN
 Generaltechnicaldescription

Pump Off, or no The engine speed is reduced to 850rpm after 10seconds

boommovement (workssetting), when you
− reduce the delivery rate 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.

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

>75% 1350rpm−maximum engine speed
0−75% 1350rpm
0% 850rpm (after 10seconds)

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

Adjusting the engine If you change the engine speed manually using the remote control,
speed manually this manually set engine speed is maintained until you:
− adjust the delivery rate at the rotary controller again,
− disengage the power take−off,
− switch off the ignition.

BP21_672_0503EN 347
 Generaltechnicaldescription

3.5.4 High–pressure water The dry running cut−out prevents the high−pressure water pump run

pump dry–running ning dry if the water tank is empty.
cut–out

MP02_295_0502EN 1

No. 0 Designation
Symbol for the high−pressure water pump dry running cut−
1
out in the EGD on the control cabinet
2 Ergonic Graphic Display (EGD)

348 MP02_295_0502EN
 Generaltechnicaldescription

Special features of the high–pressure water pump dry running cut–out

The high−pressure water pump can only be switched on if the follow

ing switch−on conditions are fulfilled:
− Power take−off is switched on
− Water tank is sufficiently full

The high−pressure water pump will switch off or cannot be switched

on if the water level drops below the level of the fill−level sensor. This
ensures that the high−pressure water pump is not damaged by inad

vertently being allowed to run dry.

The dry running cut−out can be overridden using the manual water
pump emergency operation" at the pump control system if the fill−
level sensor fails.

MP02_295_0502EN 349
 Generaltechnicaldescription

3.5.5 Control panel You can control the pump functions from the control panel. If a func

tion is active, the associated red indicator lamp will light up.

2 3

1
4

5 6 7 8

10

11

18 17 16 15 14 13 12

MP02_261_0404EN 1

Operating/
No. 0 Meaning/Function
control element
1 Power socket, 1−pin Connection for working light
2 Round socket, 4−pin Connection for vibrator
3 Female connector Connection for remote control
4 Momentary−contact switch EMERGENCY SHUT−DOWN
5 Push−button Reverse pumping
6 Push−button Pump On − Off
7 Push−button Agitator anticlockwise rotation
8 Push−button Agitator clockwise rotation
9 Display Mixer drum speed of rotation
→

350 MP02_261_0404EN
 Generaltechnicaldescription

2 3

1
4

5 6 7 8

10

11

18 17 16 15 14 13 12

MP02_261_0404EN 2

Continued
Operating/
No. Meaning/Function
control element
10 Display Output
11 Push−button Reduce − Increase output
12 Push−button Pump Off
13 Push−button Horn + deactivate EMERGENCY SHUT−DOWN
14 Push−button Vibrator On − Off
15 Push−button Reduce engine speed
16 Push−button Increase engine speed
17 Push−button High−pressure water pump On − Off
18 Red indicator lamp Operating state display

MP02_261_0404EN 351
 Generaltechnicaldescription

Special features of the control panel

Pump On − Off / Re
The functions of the Pump On − Off" and Reverse pumping" push
verse pumping buttons depend on the switch position of the Local control − 0 − Re

mote control" toggle switch on the control cabinet.
− If the switch position on the control cabinet is local control", the
pump can be switched on and off and reverse pumping can be
selected from the control panel.
− If the switch position on the control cabinet is remote control", the
pump can only be switched off and the pump cannot be switched
on, reverse pumping cannot be selected from the control panel.

Restarting the pump If you have pressed the EMERGENCY SHUT−DOWN button, you may
after EMERGENCY only start the pump up again as described below:
SHUT−DOWN − unlock the EMERGENCY SHUT−DOWN button by turning it,
− press the Horn + deactivate EMERGENCY SHUT−DOWN" push−
button,
− switch the pump off and then restart it using the Pump On−Off"
push−button.

352 MP02_261_0404EN
 Generaltechnicaldescription

3.5.6 Control panel on the

outside of the ma-
chine

1 2 3

MP02_280_0411EN 1

Operating/ Belongs
No. 0 Meaning/Function
control element with no.:
1 Toggle switch Increase − Reduce engine speed
2 Toggle switch Mix − Empty mixer drum
3 Toggle switch Override hopper fill−level sensor −
Stop mixer drum

MP02_280_0411EN 353
 Generaltechnicaldescription

Special features of the control panel on the outside of the machine

Increase − Reduce The Increase − reduce engine speed" toggle switch is not activated
engine speed" unless the speed of rotation regulation toggle switch is switched on.
You can vary the speed of the engine on the Increase − Reduce en

gine speed" toggle switch.

Note
The toggle buttons/switches listed below are activated if either the
speed of rotation regulation toggle switch is switched on or the
power take−off is switched on.

Mix − Empty mixer You can use the Mix − Empty mixer drum" toggle switch to adjust
drum" the speed of the mixer drum. The speed is adjusted gradually. To
stop the mixer drum slowly, hold the switch in the Empty" position
until the mixer drum stops. If you press the switch for too long, the
mixer drum will begin to rotate in the opposite direction.

Stop mixer drum" Use the Stop mixer drum" toggle switch to stop the mixer drum pre

cisely.

Override hopper fill− You can use the Override hopper fill−level sensor" toggle switch to
level sensor" empty the mixer, even if the hopper fill−level sensor indicates
Hopper full" and stops the mixer. This function is especially useful if
the sensor is particularly contaminated.

354 MP02_280_0411EN
 Generaltechnicaldescription

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

2 ÁÁ
ÁÁ
10
3
9

12 8 11
4

7 5

6 MP02_299_0407EN 1

Operating/ Belongs
No. 0 Meaning/Function
control element with no.:
1 Joystick Boom control
2 Rotary controller Set the boom speed if no6 is switched to 6
the Snail" switch position
3 Toggle switch Pump On − Off / Reverse pumping
4 Toggle switch Horn + deactivate EMERGENCY SHUT−
DOWN / Vibrator On − Off
5 Rotary controller Increase − Reduce output
6 Toggle switch Preselect boom speed: 2
Snail = 0−100% / Hare = 100%
7 Toggle switch (optional) Mix − Empty mixer drum
8 Toggle switch Override hopper fill−level sensor − Stop
mixer drum
9 Locally latched toggle Boom functions − Support leg control
switch
10 Momentary−contact EMERGENCY SHUT−DOWN
switch
11 Momentary−contact Increase − Reduce engine speed
switch
12 Momentary−contact Engine On − Off
switch

MP02_299_0407EN 355
 Generaltechnicaldescription

Special features of the cable remote control

Restarting the pump The red Fault" indicator lamp lights up and the green Pump run

after EMERGENCY ning" indicator lamp flashes when the EMERGENCY SHUT−DOWN
SHUT−DOWN button is pressed. You may only start the pump up again as de

scribed below:
− unlock the EMERGENCY SHUT−DOWN button by turning it,
− press the Horn + deactivate EMERGENCY SHUT−DOWN" toggle
switch (red indicator lamp goes out),
− switch the pump off and then back on again at the Pump
On−Off" toggle switch (pump runs and the green indicator lamp
lights up).

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

Joystick The two joysticks can be used to control the individual boom func

tions. You can control some of the boom functions for 3 and 4 arm
booms by moving and rotating the joysticks.

356 MP02_299_0407EN
 Generaltechnicaldescription

Mix − Empty mixer You can use the Mix − Empty mixer drum" toggle switch to adjust
drum" the speed of the mixer drum. The speed is adjusted gradually. To
stop the mixer drum slowly, keep the switch in the Empty" position
until the mixer drum stops. If you press the switch for too long, the
mixer drum will begin to rotate in the opposite direction.

Stop mixer drum" Use the Stop mixer drum" toggle switch to stop the mixer drum pre

cisely.

Override hopper fill− You can use the Override hopper fill−level sensor" toggle switch to
level sensor" empty the mixer, even if the hopper fill−level sensor indicates
Hopper full" and stops the mixer. This function is especially useful if
the sensor is particularly dirty.

Preselect boom You can select different speeds of movement for the boom using the
speed" Preselect boom speed" toggle switch.
− In the Snail" position of the switch, the boom functions can be op

erated using the rotary controller (2) at a speed of between 0%
and 100% of that set in the works.
− In the Hare" position of the switch, the boom functions are oper

ated at 100% of the speed set in the works.

MP02_299_0407EN 357
 Generaltechnicaldescription

3.5.8 Radio control system The transmitter for a proportional radio remote control with feedback
is described below.

ÁÁÁÁ
11
1

10
ÁÁÁÁ Á
ÁÁÁÁ ÁÁ
2

9
3 Á

12 13
14 15
8
4

7 5

6
MP02_269_0404EN 1

Operating/
No. 0
control element
1 Joystick
2 Toggle switch
3 Toggle switch
4 Toggle switch
5 Rotary controller
6 Locally latched toggle
switch
7 Toggle switch (optional)
8 Toggle switch
Belongs
Meaning/Function
with no.:
Boom control
Radio remote control unit On − Off 12
Pump On − Off / Reverse pumping
Horn + deactivate EMERGENCY
SHUT−DOWN / Vibrator On − Off
Increase − Reduce output
Preselect boom speed:
Snail = 50% of the works setting −
User−defined speed −
Hare = 100% of the works setting
Mix − Empty mixer drum
Override hopper fill−level sensor − Stop
mixer drum
→

358 MP02_269_0404EN
 Generaltechnicaldescription

ÁÁÁÁ
11
1

10
ÁÁÁÁ ÁÁ
ÁÁÁÁ ÁÁ
Á
2

9
ÁÁÁÁ 3 Á

12 13
14 15
8
4

7 5

6
MP02_269_0404EN 2

Continued
Operating/ Belongs
No. Meaning/Function
control element with no.:
9 Locally latched toggle Boom functions − Support leg control
switch
10 Momentary−contact switch Program user−defined boom speed 14
11 Momentary−contact switch STOP function
12 Yellow indicator lamp Flashing: remote control unit in service 2
Off: no contact with receiver
13 Red indicator lamp Flashing: battery flat
14 Momentary−contact switch Engine On − Off
15 Momentary−contact switch Increase − Reduce engine speed

MP02_269_0404EN 359
 Generaltechnicaldescription

Receiver

6
30501101

Operating/ Belongs with

No. 0 Meaning/Function
control element no.:
1 Female connector Antenna connection
2 Antenna with base Control signal reception 1
3 Indicator lamps Operating states and control com

mands display
4 Battery compartment Charge battery
5 Green indicator lamp Battery charge state 4
6 Female connector Connection to the control cabinet

Charge state of battery at receiver

Yellow indicator lamp The yellow indicator lamp lights up during the battery charging oper

ation.

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

360 MP02_269_0404EN
 Generaltechnicaldescription

Special features of the radio remote control

STOP button Putzmeister radio remote controls include a STOP button which has
the same function as the EMERGENCY SHUT−DOWN buttons on the
machine. This is a requirement of European standard EN60204−1.

Restarting the pump You may only start the pump up again as described below if you
after STOP have pressed the STOP button:
− release the STOP button by turning it,
− switch the remote control unit off and back on again,
− press the Horn + deactivate EMERGENCY SHUT−DOWN" toggle
switch,
− switch the pump off and then restart it using the Pump On−Off"
toggle switch.

Frequency change 12 frequencies on the frequency band have been assigned to this
radio remote control. As soon as you switch the transmitter off or
press the STOP button on the transmitter, the link between the trans

mitter and receiver is broken. The radio remote control automatically
advances to the next frequency when you switch the transmitter
back on.

Additional antennae You must maintain a minimum clearance of 1m between the radio
remote control antenna and any additional antennae (e.g. radio, tele

phone) you fit, as otherwise these may interfere with the radio remote
control.

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

Joystick The two joysticks can be used to control the individual boom func

tions. You can control some of the boom functions for 3 and 4 arm
booms by moving and rotating the joysticks.

MP02_269_0404EN 361
 Generaltechnicaldescription

Mix − Empty mixer You can use the Mix − Empty mixer drum" toggle switch to adjust
drum" the speed of the mixer drum. The speed is adjusted gradually. To
stop the mixer drum slowly, keep the switch in the Empty" position
until the mixer drum stops. If you press the switch for too long, the
mixer drum will begin to rotate in the opposite direction.

Stop mixer drum" Use the Stop mixer drum" toggle switch to stop the mixer drum pre

cisely.

Override hopper fill− You can use the Override hopper fill−level sensor" toggle switch to
level sensor" empty the mixer, even if the hopper fill−level sensor indicates
Hopper full" and stops the mixer. This function is especially useful if
the sensor is particularly dirty.

Preselect boom You can select different speeds of movement for the boom using the
speed" Preselect boom speed" toggle switch.
− In the Snail position of the switch, the boom functions are operated
at 50% of the speed set in the works.
− In the Hare position of the switch, the boom functions are operated
at 100% of the speed set in the works.

362 MP02_269_0404EN
 Generaltechnicaldescription

Program user−defined You can program your own speed for each of the boom functions
boom speed using the Program user−defined boom speed" toggle switch.
− Program the maximum boom speeds with the toggle switch in the
upper position.
− Program the minimum boom speeds with the toggle switch in the
lower position.

Programming your own Each boom movement must be programmed individually.

boom speed
Programming a maximum speed:

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

speed".

" Press and hold the Program user−defined boom speed"

toggle switch upwards.

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

" Release the toggle switch first and then the joystick.

Programming a minimum speed:

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

speed".

" Press and hold the Program user−defined boom speed"

toggle switch downwards.

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

stick deflection.

" Release the toggle switch first and then the joystick.

MP02_269_0404EN 363
 Generaltechnicaldescription

Now when you set the Preselect boom speed" toggle switch to the
central position and move the joystick to its full deflection, the boom
movement will be executed at the maximum speed of movement you
have just programmed. If you move the joystick only slightly, the
boom movement will be executed at the minimum speed of move

ment you have just programmed.

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

Inhibiting individual arm If you move the joystick only very slightly so that the boom does not
movements move when you are programming the maximum speed for a boom
movement, this direction of movement will be inhibited.

364 MP02_269_0404EN
 Generaltechnicaldescription

3.5.9 EMERGENCY SHUT– There are a number of EMERGENCY SHUT−DOWN buttons on the
DOWN button machine. These are located:
− on every support control block
− on the cable and radio remote control systems
− on the control box in the steps

Some possible positions of the EMERGENCY SHUT−DOWN button

are shown in the illustration below.

Caution
Familiarize yourself with the positions of the EMERGENCY SHUT−
DOWN buttons on your machine.

ÁÁÁ
Á
Á Á

MP02_264_0404EN 1

EMERGENCY SHUT−DOWN button

Note
You need only press one of the EMERGENCY SHUT−DOWN buttons
to trigger an EMERGENCY SHUT−DOWN of the machine.

To release the EMERGENCY SHUT−DOWN condition again, you

must unlock the EMERGENCY SHUT−DOWN button that has been
pressed by turning it, then press the Horn + deactivate EMERG

ENCY SHUT−DOWN" button.

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

MP02_264_0404EN 365
 Generaltechnicaldescription

The following actions are triggered in the truck, pump and boom sys

tems when you press one of the EMERGENCY SHUT−DOWN but

tons:

Range Action

Truck − The engine speed drops to idle.

− All control and switch boxes are electrically
blocked.
Pump − The concrete pump is blocked and the delivery
pistons / rotor pump stop.
− The change−over valve is disconnected.
Boom − The boom control block is disconnected.
− All control elements, with the exception of Horn
+ deactivate EMERGENCY SHUT−DOWN" are
shut down at the remote control system. All sig

nal lamps at the radio remote control unit go
out.
− All control elements, with the exception of Horn
+ deactivate EMERGENCY SHUT−DOWN" are
shut down at the cable remote control system.
The Fault" signal lamp lights up at the cable
remote control and the Pump is not running"
signal lamp flashes.
− The boom pump transports hydraulic fluid in
depressurized circulation (maximum15bar)
through the boom control block inlet module to
the tank. Emergency operation of the boom
functions is ensured by simultaneous manual
operation of the operating mode selector valve
and the corresponding boom arm valve.

366 MP02_264_0404EN
 Generaltechnicaldescription

Danger
The machine is only switched off electrically when one of the
EMERGENCY SHUT−DOWN buttons is pressed. Although this
causes all the electrically actuated hydraulic valves to be switched
off, an uncontrolled sinking of the boom caused by leakages in the
hydraulic system, for instance, cannot be prevented in this way.

In no event should you first press the EMERGENCY SHUT−DOWN

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

MP02_264_0404EN 367
 Generaltechnicaldescription

3.5.10 Agitator safety cutout
(RSA)
The agitator safety cutout consists of a switching cam and a pres

sure roller switch. The switching cam is fastened to the hinge pin of
the grille, the pressure roller switch to the hopper. The pressure roller
switch is acted on as soon as you open the grille. This causes the
agitator to halt and the pressure to be dumped from the accumulator,
ie the transfer tube will no longer be able to switch over. In addition,
the delivery pistons return to the end position and the concrete
pump halts. You must switch the concrete pump off and back on
again to re−start it.

1 2 3 4

MP02_103_9909EN 1

No 0 Designation
1 Hopper
2 Grille hinge pin
3 Switching cam
4 Pressure roller switch

Danger
The pressure roller switch must always be clean and free to move.
Inaddition, the pressure roller switch must always be in contact with
the switching cam. If the pressure roller switch is defective, the agita

tor safety cutout may not function, or the agitator and the transfer
tube may come to a halt during pumping operations.

368 MP02_103_9909EN
 Generaltechnicaldescription

3.6 Hydraulic control The hydraulic control devices and operating elements on this ma

devices chine are described on the following pages. The overview 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.
− Pump control system
− Support control block
− Boom functions control block
− Emergency hydraulic ports
− Output controller
− Transfer tube damping

Note
Further control devices and components are described in the Elec

trical control devices" (from page 320) and Other components"
(from page 377) sections.

MP02_108_0410EN 369
 Generaltechnicaldescription

3.6.1 Pump control system The hydraulic control valves are built into the pump control system.
The emergency control lever is only required during emergency
manual operation if the machine’s control system fails.

Note
Depending on the equipment on the machine, the pump control sys

tem may be fitted at a different location. You will find the location in
the overview at the start of this chapter.
The sequence of emergency operations may be from right to left or
vice versa. It may also be the case that the pump control system is
installed rotated through 90°. Familiarise yourself with the functions
of the pump control system by reading the notices affixed to it.

2
1
MP02_307_0503EN 1

No. 0 Designation
1 Agitator direction of rotation emergency manual operation.
2 Water pump emergency manual operation
3 Main hydraulic pump emergency control lever
4 Agitator emergency manual operation

370 MP02_307_0503EN
 Generaltechnicaldescription

Special features of the pump control system

Main hydraulic pump If the pump control system fails, operate the emergency control
emergency control lever(3) as follows:
lever

3a
3
3b

MP02_307_0503EN 2

No. 0 Designation
3 Main hydraulic pump emergency control lever
3a Switch position Reverse pumping
3b Switch position Pumping

MP02_307_0503EN 371
 Generaltechnicaldescription

3.6.2 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.

2 3 4
22103101

No. 0 Designation
1 Preselect lever for support function On−Off
2 Lower and raise forward support foot
3 Lower and raise rear support foot
4 Extend and retract forward support leg
5 EMERGENCY SHUT−DOWN button

Note
The support legs are extended by a cable. The cable should not be
greased, as otherwise the cable drum will slip.

372 MP02_019_0401EN
 Generaltechnicaldescription

Special features of the support control block

Two−hand control de
The support control block is designed as a two−hand control device,
vice 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 spring−loaded, i.e. the valves are
automatically reset to the zero position when you release the levers.

Direction of operation

MP02_019_0401EN 1

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.

MP02_019_0401EN 373
 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.

374 BP21_782_0407EN
 Generaltechnicaldescription

3.6.3 Boom functions The control block can be operated manually and thus provides
control block security of operation if a malfunction occurs in the remote control
system.

MP02_267_0411EN 1

No. 0 Designation
1 Support or boom function On − Off
2 Slew boom Clockwise − Anti−clockwise
3 Arm 1 Up − Down
4 Arm 2 Up − Down
5 Arm 3 Up − Down

MP02_267_0411EN 375
 Generaltechnicaldescription

Danger
Be aware that the boom functions operated manually at the boom
control block will disable the functions of the same name on the re

mote control.
Only use the manual operation of the boom control block in excep

tional cases and in emergencies (e.g. malfunctions on the remote
control).
If someone else is operating the boom control block manually, you
will no longer be able to control boom movement from the remote
control.

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°. Fami

liarise yourself with the functions of the control block by reading the
notices affixed to it.

376 MP02_267_0411EN
 Generaltechnicaldescription

3.7 Other components The other components of this machine are described on the follow

ing pages. The overview 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.
− End hose
− Pressurized water system
− High−pressure water pump
− Vibrator
− Hydraulic fluid radiator
− Chute
− Mixer lever
− Water box

Note
Further control devices and components are described in the
Hydraulic control devices" (from page 369) and Electrical
control devices" (from page 320) sections.

MP02_109_9909EN 377
 Generaltechnicaldescription

3.7.1 End hose The machine is fitted with an end hose permitted for the required sta

bility. This depends on a number of factors:
− End hose length
− End hose diameter
− Self−weight of the end hose

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
It is forbidden, under normal conditions of use, to extend the end
hose or to fit an end hose longer than that specified on the rating
plate. It is further forbidden to use an end hose with a greater diam

eter or higher weight. The machine can tip over if you use a pro

hibited end hose.

The end hose is inserted in its retainer when the placing boom is
folded. You must remove the end hose from its retainer before un

folding the placing boom. Insert the end hose back into its retainer
when folding the placing boom.

MP02_104_0503EN 1

End hose in its retainer

378 MP02_104_0503EN
 Generaltechnicaldescription

End hose with flow End hoses may not be fitted with any extension coupling, outlet
restrictor shoes or other dangerous outlet fitting. You can use the modified
Putzmeister end hose with flow restrictor if you wish nevertheless to
achieve a uniform flow of the concrete for filling hollow blocks.

ÂÂÂ
ÂÂÂ
ÂÂÂ
ÂÂÂ
ÂÂÂ
ÂÂÂ
1

ÂÂÂ
ÂÂÂ
2

3 ÂÂÂ
4

MP02_104_0503EN 2

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

Danger
The end hose with flow restrictor may only be used for filling hollow
blocks. The rubber protective sleeve must always be pulled fully
down over the push−in spout, whether or not you are using the flow
restrictor. The end hose may no longer be used if the protective
sleeve is damaged or missing entirely.

MP02_104_0503EN 379
 Generaltechnicaldescription

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

ÂÂÂÂ
2 ÂÂÂÂ
ÂÂÂÂ
3

ÂÂÂÂ
ÂÂÂÂ
ÂÂÂÂ
4

ÂÂÂÂ MP02_104_0503EN 3

No. 0 Designation
1 Snap hook
2 Retaining rope
3 Push−on connection
4 Hose clamp

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

cured 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.

380 MP02_104_0503EN
 Generaltechnicaldescription

3.7.2 Pressurized water The pressurized water system replaces the flushing water pump.
system Thewater tank is pressurized by compressed air which is fed from
the truck. This means that the water is delivered at the pressure set
on the air pressure limiting valve.

9 8

1 2 3 4 5

MP02_025_9712EN 1

No 0 Designation
1 Compressed air line to the water tank
2 Vent line
3 Pressure gauge
4 Isolating valve
5 Pressure reservoir on truck
6 Compressed air line from truck
7 Air pressure limiting valve
8 Water hose
9 Water tank

Note
When filling the water tank, the shut−off valve must be open so that
air can escape from the water tank.

MP02_025_9712EN 381
 Generaltechnicaldescription

3.7.3 High–pressure The high−pressure water pump generates the pressurized water
water pump used to clean the machine.

Water system

1
2 3

4 5 6 7 8 9 10 11

BP21_500_0212EN 1

No. 0 Designation
1 Shut−off valve
2 Air vent cock
3 High−pressure water pump
4 Water filter
5 Drain cock
6 Pressure gauge
7 Emergency operation
8 High−pressure hose
9 Gun
10 Lance
11 Spray nozzle

382 BP21_500_0212EN
 Generaltechnicaldescription

High–pressure
water pump 1 2

11 5

10
9

7
6

BP21_500_0212EN 2

No. 0 Designation
1 Pressure gauge
2 Pressure dump valve
3 Pressurized water delivery connection
4 Hydraulic fluid return connection
5 Heat protection valve
6 Hydraulic fluid intake connection
7 Intake water connection
8 Oil filler
9 Oil inspection glass (rear side of housing)
10 Oil drain plug
11 Water filter housing

Caution
The pressure dump valve is set to 100bar at the works and secured
using a lock nut. This setting must not be altered. The hydraulic sys

tem could be damaged if the pressure dump valve is incorrectly ad

justed.
The pumping rate, operating pressure and nozzle are matched and
must not be altered.

BP21_500_0212EN 383
 Generaltechnicaldescription

Note
The high−pressure water pump is equipped with a pressure dump
valve which is set to 100bar. If the gun is closed and 100bar is
exceeded in the water system, the pressure dump valve opens a
bypass to the intake side of the high−pressure water pump. Although
the water in the high−pressure water pump circulates at low pres

sure, there is pressure in the high−pressure hose.
If the gun is opened, the pressure in the high−pressure hose
decreases, the pressure dump valve closes the bypass and the
pressure in the high−pressure water pump reaches operating
pressure.

A heat protection valve prevents the high−pressure water pump from

overheating when the water is circulating through the bypass.
At64°C, the heat protection valve opens and releases the hot water,
allowing cold water in from the intake water line. This process is
intentional and does not mean that there is a malfunction.

Caution
You must drain the residual water from the high−pressure water
pump if there is a risk of freezing, even if the machine is operating
ona construction site.

Do not exceed the maximum values for the following operating

parameters:
 an engine speed of 1750rpm,
 pressure of 100bar,
 the permitted water temperature of 60°C,
 intake pressure of 8bar.

This high−pressure water pump is not suitable for pumping drinking

water or food.
The liquid drawn in must not contain sand or other solids in suspen

sion. Solid particles would affect pumping operations and may
damage components of the high−pressure water pump, e.g. seals
and pistons.

384 BP21_500_0212EN
 Generaltechnicaldescription

3.7.4 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 is located at the control box at the steps near the
hopper.

1
3

MP02_105_9909EN 1

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.

MP02_105_9909EN 385
 Generaltechnicaldescription

3.7.5 Hydraulic fluid radi- Some of the hydraulic fluid in the machine first flows through a hy

ator draulic fluid radiator before it returns to the reservoir. The fan on the
hydraulic fluid radiator can be switched on by two temperature sen

sors or manually.
− A 70_C temperature sensor is fitted on the hydraulic fluid radiator.
This temperature sensor measures the temperature of the main
hydraulic pump flushing fluid.
− The second temperature sensor is mounted in the flushing fluid
line of the main hydraulic pump and switches at 65_C and 90_C.
This temperature sensor only measures the temperature of the
flushing fluid flowing back from the main hydraulic pump.

1 2

T
I
3

MP02_266_0411EN 1

No. 0 Designation
1 Radiator
2 Temperature sensors
3 Main hydraulic pump flushing fluid

This circuit offers both a redundant safety system and cooling of the
hydraulic fluid if only the concrete pump is running.
− The fan on the hydraulic fluid radiator switches on once the flush

ing fluid from the main hydraulic pump reaches a temperature of
65_C.
− The fan also switches on if the temperature sensor on the main hy

draulic pump is measuring less than 65_C, but the temperature
sensor on the hydraulic fluid radiator is measuring 70_C.
− The concrete pump switches itself off if the flushing fluid from the
main hydraulic pump has reached a temperature of 90_C.

386 MP02_266_0411EN
 Generaltechnicaldescription

20204201

No. 0 Designation
1 Symbol for the hydraulic fluid radiator in the EGD on the
control cabinet
2 Hydraulic fluid return circuit
3 Fan
4 70_C temperature sensor
5 Hydraulic fluid supply circuit

MP02_266_0411EN 387
 Generaltechnicaldescription

Note
You may switch on the fan at the control cabinet, whatever the fluid
temperature, should you wish to cool the hydraulic fluid before it has
reached 65_C or 70_C as a precautionary measure. As soon as the
fan begins running, this is shown on the control cabinet.

Leave the truck engine running during breaks in pumping or when

pumping is completed until the fan motor switches itself off.

The hydraulic fluid is also cooled by the water in the water box. The
hydraulic fluid warms up the piston rods for the drive cylinders.
These are flushed, and thus cooled, by the water in the water box on
each stroke movement. This also cools the hydraulic fluid. You
should therefore change the water in the water box at frequent inter

vals.

388 MP02_266_0411EN
 Generaltechnicaldescription

3.7.6 Chute The chute can be slewed and its height adjusted manually or
hydraulically.

Hydraulic height
adjustment

MP02_029_9712EN 1

No 0 Designation
1 Hydraulic hand pump
2 Slewing locking mechanism
3 Chute

Hydraulic hand pump

MP02_029_9712EN 2

No 0 Designation
1 Hydraulic hand pump drain valve

MP02_029_9712EN 389
 Generaltechnicaldescription

Manual height
adjustment

MP02_029_9712EN 3

No 0 Designation
1 Height adjustment spindle
2 Slewing locking mechanism
3 Chute

Height adjustment
spindle

MP02_029_9712EN 4

390 MP02_029_9712EN
 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 pumps and trailer concrete 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 signaller to
guide you. If necessary, have the route blocked or secured by assist

ants. Have the site management arrange for the removal of any ma

terials or equipment that hinder your approach.

Agree clear hand signals with the signaller before moving off.

4.1.1 Hand signals

10000331

See the chapter on Hand signals for driving" for hand signals

MP04_002_9801EN 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
inflation pressures, etc).

" Check that the accessories and the load are secure.

" Check that the support legs are secured in the driving position.

" Observe the permissible gross laden weight.

" Check that the oil and water tanks are not leaking and that they
are securely closed.

" Switch off the power take−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 (eg spring pins on all snaplocks).

42 MP04_002_9801EN
 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 must never be driven with the placing boom in the
unfolded position. This may cause the truck to tip over.

Never drive the truck with the boom unfolded.

MP04_002_9801EN 43
 Driving,towingandloading

4.2 Hand signals It is often necessary to have a marshaller 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 marshaller
and machine operator. Below you will find some suggestions for
hand signals to be used when driving.

Stop Extend both arms out to the

side.

10000306

Drive to the left With the arm crooked, point

with the thumb in the direction
the truck should steer.

10000301

Drive to the right With the arm crooked, point

with the thumb in the direction
the truck should steer.

10000302

44 BP04_003_9508EN
 Driving,towingandloading

Drive towards With the arm crooked, wave the

the signaller palm in the direction the truck
should drive.

10000303

Drive away from With the arm crooked, wave the

the signaller palm in the direction the truck
should drive.

10000304

Clearance With the arm crooked, indicate

the distance to an obstacle with
the palms of the hands.

10000305

BP04_003_9508EN 45
 Driving,towingandloading

4.3 Towing The truck may only be towed in accordance with the truck manufac

turer’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 MP04_004_9801EN
 Driving,towingandloading

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.

MP04_004_9801EN 47
 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.

48 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 49
 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 Before starting The vacuum system is started up as soon as the power take−off is
engaged. You must therefore check that the rotor pump is working
properly and inspect the pump tube for damage before you engage
the power take−off.

Caution
If the pump tube is damaged there may be concrete residue in the
rotor housing. Since the vacuum system generates an underpressure
as soon as the power take−off is engaged, concrete residue may be
sucked through the pneumatic lines.
This leads to clogging of the pneumatic lines and the air filter cartridge.

1 2 3 4

MP07_077_0308EN 1

No. 0 Designation
1 Rotor housing
2 Pneumatic line
3 Vacuum pump
4 Air filter cartridge

MP07_077_0308EN 53
 Operation

Danger
Risk of injury by crushing and shearing caused by moving machine
parts.
Never reach into the rotor pump assembly opening when the pump
is in operation.
Do not place any object or tools in the rotor pump assembly opening
when the pump is in operation. These objects may be trapped by the
rotor and become entangled in it. They might then hit you or be torn
from your hands and cause you injury.

Caution
The rotor housing must be dry.
Check the rotor housing thoroughly for moisture (residual water,
condensate water).
Clean the rotor housing if necessary.

" Check the interior of the rotor housing for moisture and
concrete residue.

The following circumstances may arise in the rotor housing:

− You did not find any moisture or concrete residue, you may start
up the rotor pump.
− You did find moisture and concrete residue, you must follow the
operating procedure described below:

" Clean the rotor housing.

Maintenance card: Replacing the pump tube

Maintenance card: Adjusting the pressure rollers

" Replace the pump tube.

" Clean the pneumatic line.

" Clean the air filter cartridge (replace the air filter cartridge if
required).

54 MP07_077_0308EN
 Operation

5.1.4 NA power take–offs The NA power take−off is mounted on the rear of the gearbox and is
dependent on the transmission.

Note
Let the engine warm up at 800 − 1000 rpm to allow it to reach operat

ing pressure (air pressure 7 bar). Follow the Operating Instructions
for the engine.

Caution
The following points must be complied with in order to prevent dam

age when switching on the power take−off:
 The operating pressure must be available on the truck before the
power take−offs are engaged (see truck manufacturer’s technical
data). In addition, the concrete pump must be switched off and
the output turned down to 0".
 Only engage the NA power take−off (boom hydraulic pump) with
the engine running and the clutch depressed.
 The power take−offs must not be engaged when the engine is
started.

Note
You must apply the parking brake before you engage the power
take−off if your truck engine is equipped with electronic diesel con

trol (EDC). Otherwise you will not be able to increase the engine
speed during pumping operations. This is also the case if you re

lease the parking brake and apply it again while the power take−off
is engaged.

" Apply the parking brake.

" Start the engine.

" Depress the clutch pedal and wait for about six seconds.

MP07_081_0410EN 55
 Operation

5.1.5 Operating and control This illustration shows examples of operating and control elements
elements for power for power take−offs. The mounting location may differ on different
take–offs truck models.

Note
Be guided by the symbol on the power take−off selector and observe
the truck manufacturer’s Operating Instructions.

1 2 3 4

MP07_081_0410EN 1

No. 0 Designation
1 Indicator lamp in dashboard: Power take−off is engaged
2 Power take−off selector 1" NA
3 Power take−off selector 2" NA
4 Switch for engine operating speed controller (ADR)

" Engage the power take−offs.

" Release the clutch pedal again slowly.

Note
The procedure for disengaging the power take−offs is analogous but
in the reverse sequence.

56 MP07_081_0410EN
 Operation

Mixer drum speed This machine is fitted with a special circuit for regulating the speed
regulation of the mixer drum. You can control the mixer drum rotation speed
using the following equipment depending on the switch position of
the power take−off selector and the switch for the engine operating
speed controller (ADR):
− Engine speed switch box
− Remote control
− Control panel in the central console (optional)
− Control panel on the outside of the machine (optional)

Speed of rotation regulation ADR"

Power take−offs1 If both the power take−off selectors are switched on (pumping oper

and2 engaged ations), the engine speed is already restricted to the engine operat

ing speed and the engine operating speed toggle switch does not
function.

Power take−offs 1 If both the power take−off selectors are switched off (driving oper

and 2 disengaged ations), the engine operating speed regulator toggle switch in the
driver’s cab can be operated, so that the engine speed can be re

stricted to engine operating speed. The engine speed can be ad

justed using the Increase − Reduce engine speed" toggle switch on
the control panel on the outside of the machine".

MP07_081_0410EN 57
 Operation

5.1.6 Starting the rotor You start up the vacuum system as soon as you engage the power
pump up take−off. If you have not found any damage to the rotor housing or
pump tube, you may prepare to pump.

MP07_022_0301EN 1

No. 0 Designation
1 Vacuum meter
2 Ventilation cock

" Close the ventilation cock(2) on the rotor housing.

An underpressure is generated in the rotor housing.

Note
The rotor pump is ready for operation as soon as an underpressure
of 0.5−0.6bar has been generated inside the rotor. You will be able
to see this on the vacuum meter(1) on the rotor pump.

58 MP07_022_0301EN
 Operation

5.1.7 Remote control Depending on your machine’s equipment, you are able to operate it
− using radio remote control,
− using cable remote control, or
− directly from the machine in emergency operation.

Hazard warnings The following hazard warning apply for all types of remote control.

Danger
Before starting to use the remote control, press the EMERGENCY
SHUT−DOWN button on the remote control and shift all control and
monitoring devices on the remote control to the 0" position. The
boom or the pump can otherwise execute unintended movements as
soon as the remote control is switched on.

Before switching on the remote control, turn the Boom speed toggle
switch" to the snail symbol and, if fitted, turn the rotary controller to
0". This ensures that the first boom movements after the remote
control is switched on will be executed slowly and you will be able to
get used to them.

Caution
Carry the remote control in such a way that no control elements can
be actuated unintentionally. Do not damage the remote control
cable. Incorrect functions may otherwise occur.
Never put the remote control down when the machine is in ready
mode. If this cannot be avoided in exceptional circumstances, press
the EMERGENCY SHUT−DOWN button in, disconnect the remote
control and lock the remote control unit away in the driver’s cab.

BP07_051_9412EN 59
 Operation

Proportional radio Proportional control means

remote control − the boom moves slowly on a small movement of the boom control
levers,
− the boom moves at its maximum speed on a large movement of
the boom control levers.

Starting up The procedure for starting operations with the machine using radio
remote control is as follows:

10504401

Switch on radio remote control

" Switch the Local−Remote switch on the switch box in the

driver’s cab to Remote.

" Switch the radio remote control on.

" Unlock the STOP button by turning it.

" Sound the horn.

Only now can you execute any further function on the radio remote
control.

510 MP07_006_0102EN
 Operation

Boom speed You can halve the boom speed set in the works by operating the
boom speed adjust toggle switch.

10504402

Boom speed adjust toggle switch

" Set the switch to the Snail" symbol to halve the boom speed.

" Set the switch to the Hare" symbol to work with the boom
speed set in the works.

MP07_006_0102EN 511
 Operation

Restarting the pump If you have stopped the machine while pumping by pressing the
STOP button on the radio remote control, you must proceed as
follows for restarting:

10504403

Press: lock the STOP button

Turn: unlock the STOP button

" Unlock the STOP button by turning it.

" Sound the horn.

" Switch the pump off first, and then back on again.

512 MP07_006_0102EN
 Operation

Cable remote control You can only execute boom movements in black and white with the
cable remote control, ie the boom always moves at its maximum
speed, no matter how much you move the boom control lever.

Danger
Black−and−white control can lead to jerky movements and significant
swaying of the boom, which represents a high risk of an accident to
the operator guiding the hose. Turn the toggle switch boom speed to
the snail symbol and the rotary controller to 0" before beginning to
use the remote control.

10504501

Toggle switch and rotary controller for adjusting boom speed.

MP07_007_9712EN 513
 Operation

Starting up You must proceed as follows to start operations with the machine
using cable remote control:

Note
On some control cabinets, the socket into which the cable remote
control is plugged is located on the control cabinet casing. On some
control cabinets the socket is fixed to the truck superstructure and
connected to the control cabinet by a cable.

10504600

Connecting the cable remote control

" Plug the cable remote control plug into the control cabinet
andsecure it.

" Plug the connector into the cable remote control unit and
secure it.

" Switch the Local−Remote switch on the switch box in the

driver’s cab to Remote.

" Unlock the EMERGENCY SHUT−DOWN button by turning it.

" Sound the horn.

Only now can you execute any further function on the remote control.

514 MP07_007_9712EN
 Operation

Boom speed You can adjust the boom speed set in the works to any speed by
means of the boom speed rotary controller.

The procedure for adjusting the speed of boom movement is as

follows:

10504501

Toggle switch and rotary controller for adjusting boom speed.

" Press the EMERGENCY SHUT−DOWN button on the remote

control.

" Set the toggle switch to the Snail" symbol.

" Turn the rotary controller to 0".

" Switch on the cable remote control system.

" Set the boom speed required by trial and error using the rotary
controller.

MP07_007_9712EN 515
 Operation

Restarting the pump If you have stopped the machine while pumping by pressing the
EMERGENCY SHUT−DOWN button on the remote control, you must
proceed as follows for restarting:

10504502

Press − Lock EMERGENCY SHUT−DOWN

Turn − Unlock EMERGENCY SHUT−DOWN

" Unlock the EMERGENCY SHUT−DOWN button by turning it.

" Sound the horn.

" Switch the pump off first, and then back on again.

516 MP07_007_9712EN
 Operation

5.2 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 517
 Operation

5.2.1 Space requirement

ÁÁÁ ÁÁÁ 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
ÁÁÁ
ÁÁÁ ÁÁÁ
ÁÁÁ ÁÁ
ÁÁ ÁÁ
ÁÁ
ÁÁÁ ÁÁÁ ÁÁ ÁÁ
12100801

The support legs must always be fully swung out and extended

1 2

MP07_054_9903EN 1

Space requirement for the TMM 26

1 Extent of forward supports = 3.8 m
2 Extent of rear supports = 2.3 m

518 MP07_054_9903EN
 Operation

5.2.2 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 danger of crushing in the swing−out 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 EMERGENCY SHUT−
DOWN button if anyone enters the danger zone.

BP07_217_9702EN 519
 Operation

5.2.3 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
imaginary 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.

520 BP07_217_9702EN
 Operation

5.2.4 Safe clearance

from pits

A2T A1T

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  2  pit depth T,
− for compact, non−friable ground is A  1  pit depth T.

5.2.5 Supporting ground

22102802

No voids or other irregularities of the ground under the

supportfeet

BP07_217_9702EN 521
 Operation

22102803

Only on level supporting ground

Caution
Do not bridge voids or other ground irregularities with support blocks
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.

522 BP07_217_9702EN
 Operation

5.2.6 Support area The machine must be supported in accordance with the corner
bearing loads of the machine and the loadbearing capacity of the
supporting ground (permissible ground pressure). You will have to
extend the support area if the permissible ground pressure for a soil
type is exceeded.

Note
Use the Putzmeister support blocks and timber blocks as supporting
timbers to increase the support area.

Support block

12100501

Putzmeister support blocks are made of multi−ply glued

timber and are encased in plastic. The support blocks are
60x 60 cm in size.

BP07_217_9702EN 523
 Operation

Corner bearing load

22102900

The corner bearing load is stated on each support leg

" Ask the site management about the maximum permissible

ground pressure.

" Calculate whether the support area provided is adequate.

Note
The support area is adequate if the maximum possible ground
pressure is less than the maximum permissible ground pressure.
Themaximum possible ground pressure is calculated as follows:

Machine corner bearing load

Max possible ground pressure =
Max.
Support area

524 BP07_217_9702EN
 Operation

Calculation example 1 Permissible ground pressure, 600 kN/m 2

as stated by the site management

Support area (= support plate area) 0.0875 m 2

Machine corner bearing load 160 kN

maximum possible ground pressure 1829 kN/m 2

The maximum possible ground pressure (1829kN/m2) is greater

than the permissible ground pressure (600kN/m2). You will at least
have to increase the support area.

Calculation example 2 Permissible ground pressure, 600 kN/m 2

as stated by the site management

Support area (= support block area) 0.36 m 2

Machine corner bearing load 160 kN

maximum possible ground pressure 444 kN/m 2

In this example it is sufficient to place Putzmeister support blocks

(60cmx60cm) beneath the support feet.

BP07_217_9702EN 525
 Operation

Length of the timber The table below shows the minimum length of the timber blocks
blocks required required.

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 block as shown.The support block and
the timber blocks must always be free from grease, oil, ice, etc, as
otherwise the support leg could slip off.

12100502

526 BP07_217_9702EN
 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
Timber block lengths in cm
ground pressure kN/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
(min. 20 cm thick)
Hardcore 250
84 100 117 134 150 167
(compacted)
Clayey, coarse clay 300
84 98 112 125 139 153 167
(firm)
Mixed stone 350
With Putzmeister 84 96 108 119 131 143 155 167
(firm)
Layered gravel 400 support blocks without
84 94 105 115 125 136 146 157 167
(firm) additional timber
500 blocks 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 (egactual corner
bearing load of the machine = 180kN; you must take the timber
block length from the 200kN column from the table).

BP07_217_9702EN 527
 Operation

Example 1
Corner bearing load in kN
(see support leg) 50 75 100 125 150 175 200

Permissible
Timber block lengths in cm
ground pressure kN/m2
Undisturbed soil 100
84 125 167 209 250
Asphalt 200
84 105 125 146 167
(min. 20 cm thick)
Hardcore 250
84 100 117 134
(compacted)
Clayey, coarse clay 300
84 98 112
(firm)
Mixed stone 350
With Putzmeister 84 96
(firm)
Layered gravel 400 support blocks without
84
(firm) additional timber
500 blocks

Soil type: firmly layered gravel

Permissible ground pressure 400 kN/m 2
Machine corner bearing load 150 kN
Timber block length not required
In this example it is sufficient to place Putzmeister support blocks
(60cmx60cm) beneath the support feet.

528 BP07_217_9702EN
 Operation

Example 2
Corner bearing load in kN
(see support leg) 50 75 100 125 150 175 200

Permissible
Timber block lengths in cm
ground pressure kN/m2
Undisturbed soil 100
84 125 167 209 250
Asphalt 200
84 105 125 146 167
(min. 20 cm thick)
Hardcore 250
84 100 117 134
(compacted)
Clayey, coarse clay 300
84 98 112
(firm)
Mixed stone 350
With Putzmeister 84 96
(firm)
Layered gravel 400 support blocks without
84
(firm) additional timber
500 blocks

Soil type: compacted hardcore

Permissible ground pressure 250 kN/m 2
Machine corner bearing load 150 kN
Timber block length at least 100cm
In this example you must place 4timber blocks with a cross−section
of 15cmx15cm and a length of at least 100cm beneath the
support feet in addition to the Putzmeister support blocks
(60cmx60cm).

BP07_217_9702EN 529
 Operation

5.3 Supporting You must have read the safety regulations and have completed the
the machine operations for starting up the machine before you begin setting out
the machine supports.

Danger
The machine supports may only be used under the following condi

tions:
 the pump drive engine is running;
 the power take−off is engaged (i.e.the machine is set to pumping
operations);
 the Support" function has been selected at the remote control or
on the control block.
It is absolutely forbidden to move the support manually
(mechanically).

12101600

Do not move the hydraulic support legs manually

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 re

lease the parking brake and apply it again while the power take−off
is engaged.

" Drive the machine to the set−up site you have inspected.

" Apply the parking brake.

" Engage the power take−off.

530 MP07_011_0207EN
 Operation

5.3.1 Working range

10000800

The working range is the area in which work

is carried out with or on the machine.

Danger
Persons who remain in the working range without authorization can
be injured.
You should therefore secure the working range. Keep the working
range under constant observation.
You must cease working immediately and press the EMERGENCY
SHUT−DOWN button if unauthorized persons enter the working
range.

MP07_011_0207EN 531
 Operation

5.3.2 Remote control

2

10504701

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 Supports On".

Note
First pull up the toggle switch (1) and then press it in the direction
shown by the symbol (2).

532 MP07_011_0207EN
 Operation

5.3.3 Interlock

2
12100101

Snaplock

You must unlock the support legs before you are able to extend them
or swing them out.

" Pull out the spring pin (1).

" Pull the lever on the snaplock upwards (2).

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 swing−out support legs have

been swung out. Do not replace the spring pin; in this way the
supports will be locked automatically when they are swung back.

Before driving off, make sure that all the snaplocks are secured by a
spring pin.

MP07_011_0207EN 533
 Operation

5.3.4 Danger zone

12100300

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 danger of crushing in the swing−out 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 EMERGENCY SHUT−
DOWN 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 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.

Caution
The support legs must always be swung out or extended to their
maximum extent. Only in this way will the machine achieve the
necessary stability.

534 MP07_011_0207EN
 Operation

5.3.5 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 jeopardized at a deviation from the hori

zontal of 3_ or more.

Caution
Extend the support feet one after the other until the truck super

structure rises. The truck springs must not be under load.
The support feet are not intended for lifting the truck completely from
the ground.
To prevent the machine frame from becoming distorted, check that
no truck axles are raised after setting out the machine supports.
The tyres must be firmly seated on the ground.

MP07_011_0207EN 535
 Operation

5.3.6 Forward support legs

22103102

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

function.

" Pull lever (2) upwards to extend the forward support leg.

" Release both levers to deactivate the function.

" Do the same on the other side of the truck.

536 MP07_012_9712EN
 Operation

5.3.7 Forward support feet

22103103

1 Preselect lever
2 Lower and raise forward support foot

Proceed as follows to lower the front support feet:

" Press the preselect lever (1) downwards to activate the

function.

" Pull lever (2) upwards to lower the forward support foot.

" Release both levers to deactivate the function.

" Do the same on the other side of the truck.

MP07_012_9712EN 537
 Operation

5.3.8 Rear support feet

22103104

1 Preselect lever
2 Lower and raise rear support foot

Proceed as follows to lower the rear support feet:

" Press the preselect lever (1) downwards to activate the

function.

" Pull lever (2) upwards to lower the rear support foot.

" Release both levers to deactivate the function.

" Do the same on the other side of the truck.

Note
Extend the rear support feet only sufficient to take the load on the
rear axles, but leaving the rear wheels in contact with the ground.

538 MP07_012_9712EN
 Operation

5.3.9 Remote control

10504702

Selector switch

The support function must be disabled to continue with operations.

" 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_9509EN 539
 Operation

5.4 Function check You must check that the pump is functioning perfectly before you
on the pump start to pump concrete.

" Switch the pump on at the remote control.

" Check that the rotor is running freely at various speeds of the
power unit and positions of the output controller.

" Observe the pump tube through the inspection glasses.

Caution
Only permit the rotor to run without concrete for a short period to
avoid causing damage to the pump tube.

" Set the engine to maximum speed.

" Turn the potentiometer to maximum pumping rate.

" Measure the rotor speed over half a minute.

" Switch the pump off again.

Note
Double the value you have measured. This gives you the rotor revol

utions in a minute. This value must match the value shown on the
machine card.

540 MP07_014_9909EN
 Operation

5.4.1 Checking the A constant vacuum must be generated to ensure fault−free operation
vacuum gauge of the pump.

40600102

1 Pressure gauge
2 Ventilation cock

" Close the ventilation cock on the rotor pump.

Note
A vacuum of 0.5−0.6bar must be generated within 5−10minutes.
You will be able to read the vacuum from the pressure gauge on the
rotor pump.

MP07_014_9909EN 541
 Operation

5.4.2 Function check on the This machine is fitted with an agitator safety cutout (RSA). A pressure
agitator safety cutout roller switch is acted on as soon as you open the grille. This stops
the agitator and the transfer tube no longer switches over. In addi

tion, the delivery pistons return to the end position and the concrete
pump halts.

Danger
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.

542 BP07_462_9906EN
 Operation

BP07_462_9906EN 1

" Open the grille with the concrete pump running.

The switching cam acts on the pressure roller switch.

The agitator must come to a halt immediately.

The transfer tube must no longer switch over.

The concrete pump must run to the end position and halt.

Danger
You must stop work if you open the grille, but
 the agitator continues to run, or
 the transfer tube continues to switch, or
 the concrete pump does not run to its end position.

Note
You must switch the concrete pump off and back on again to re−start
it.

BP07_462_9906EN 543
 Operation

5.4.3 Filter functions The machine hydraulic system has one or more suction filters. The
suction filters are numbered consecutively and marked accordingly.
Each suction filter is assigned a vacuum meter with the same identifi

cation. The installation location of the vakuum meter depends on the
machine model, normally it is on the right side of the vehicle super

structure when viewed in the direction of travel. You can detect from
the vacuum meter whether the filter element needs to be replaced.

Dirty filters reduce the fluid flow considerably so that damage may
occur in the hydraulic system.

Vacuum meter for the

suction filters

10300200

Vacuum meter

Note
The filter element must be replaced if the vacuum meter indicator is
in the red zone at more than 30° C fluid temperature and the fastest
stroke time.

Environmental protection
Comply with the waste disposal regulations in force for your area
when changing the fluid filter.

544 MP07_015_0401EN
 Operation

Boom filter

10400600

Pressing down the red button

" Bring the hydraulic fluid up to operating temperature

(50°
C).

" Set the maximum pumping rate.

" Press in the red button on the filter if it is sticking out.

Note
You must replace the filter element if the red button pops out again
after a short time.
The filter is OK if the red button remains depressed.

Environmental protection
Comply with the waste disposal regulations in force for your area
when changing the fluid filter.

MP07_015_0401EN 545
 Operation

5.4.4 EMERGENCY SHUT– It is only possible to intervene rapidly in the event of danger if all the
DOWN function EMERGENCY SHUT−DOWN buttons are functioning.

Caution
The machine is no longer safe in operation if the EMERGENCY
SHUT−DOWN button is defective, as you will no longer be able to
switch the machine off quickly enough if danger threatens.
You must therefore inspect the function of the EMERGENCY SHUT−
DOWN buttons and the lever position for the boom valves (see
Function check on the boom control block") before starting work
each time.

Danger
The machine is only switched off electrically when the EMERGENCY
SHUT−DOWN button is pressed. Although this causes all the electri

cally actuated hydraulic valves to be switched off, an uncontrolled
sinking of the boom caused by leakages in the hydraulic system, for
instance, cannot be prevented in this way.

In no event should you first press the EMERGENCY SHUT−DOWN

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

Furthermore, the EMERGENCY SHUT−DOWN circuit has no influ

ence on the agitator pump, iethe agitator continues to rotate, des

pite the EMERGENCY SHUT−DOWN button having been pressed in.

546 MP07_015_0401EN
 Operation

EMERGENCY SHUT–
DOWN button

10500200

Press − lock EMERGENCY SHUT−DOWN

Turn − unlock EMERGENCY SHUT−DOWN

" Switch the pump on.

" Operate a boom function.

" Press one of the EMERGENCY SHUT−DOWN buttons.

The pump and the boom must come to a halt immediately.

" Check all EMERGENCY SHUT−DOWN buttons on the machine

and on the remote control in the same way.

MP07_015_0401EN 547
 Operation

5.4.5 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 ob

serving the levers on the boom control block.

The lever for the boom valve operated and the lever for the
operating mode selector valve must move each time.

Note
As soon as you release the boom control levers on the remote con

trol unit, the levers for the boom arm valves previously actuated and
for the operating mode selector valve must return to the central posi

tion (zero position).

The reactions of the operating mode selector valve on the boom con

trol unit are delayed by some 3 seconds if you use the cable remote
control.

548 MP07_015_0401EN
 Operation

5.5 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 extend 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

MP07_075_0212EN 1

Prohibited

Danger
Avoid the following actions. They overload the placing boom and
may lead to damage or endanger 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.

MP07_075_0212EN 549
 Operation

5.5.1 Restrictions on use Extreme weather conditions, such as gales, storms or low
temperatures restrict the use of the boom, or can even make
itsuseimpossible.

Bad weather Shift the placing boom to the rest position in the event of storms
and storms orbad weather.
− Booms with a vertical reach of 42m or more (M42 and larger)
may only be operated in wind forces up to7
(windspeed61km/h=17m/s).
− Booms with a vertical reach of less than 42m (< M42) may only
be operated in wind forces up to8
(windspeed74km/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.

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 inconvenience when walking against the
wind.
− In winds of force8 and greater, small branches break from trees
and walking outside is significantly impeded.

Cold weather The placing boom must not be used in temperatures below
minus15_C (+5_F). There is a danger of damage to the steel
(brittle fracture) and the seals throughout the system at such
extremely cold temperatures.

In addition, such cold temperatures should be considered the

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

550 MP07_075_0212EN
 Operation

5.5.2 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 halt work immediately and press the EMERGENCY SHUT−
DOWN button if anyone enters the danger zone.

MP07_075_0212EN 551
 Operation

High–voltage lines A spark can jump across from high−voltage lines even if you just
approach them and this will energize the machine and the surround

ing area. You must therefore always maintain the specified safe
clearance.

MP07_075_0212EN 2

Caution in the vicinity of high−voltage lines

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

552 MP07_075_0212EN
 Operation

Overlapping
working ranges

MP07_075_0212EN 3

Beware of overlaps

Caution
Take note of the working ranges of other construction plant
(e.g.cranes, other concrete placing booms, etc.).

Signal boom
movements

MP07_075_0212EN 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.

MP07_075_0212EN 553
 Operation

Hand signals

10000331

See the Hand signals 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 the case, you must only move the placing boom in
response to signals from a signaller.
Agree unambiguous hand signals with the signallers giving
directions.

554 MP07_075_0212EN
 Operation

5.5.3 Exceptional cases The boom control block can only be operated after the guard has
and emergencies been removed. The control block can be operated manually and
thus provides security of operation if a malfunction occurs in the
remote control system.

3 32000602

No. 0 Designation
1 Fastening bolts
2 Guard
3 Boom control block

" Undo the fastening bolts.

" Remove the guard.

" Operate the boom control block (manually).

Immediately on completion of manual operation:

" Fit the guard.

Danger
Be aware that the boom functions operated manually at the boom
control block will disable the functions of the same name on the
remote control.
Read the Boom functions control block" section of the General
technical description chapter.

MP07_075_0212EN 555
 Operation

5.5.4 Spontaneous retrac- The hydraulic fluid heats up to an average temperature of 60°−70° C
tion of the boom and during operation because of the friction in the lines.
support cylinders When the hydraulic fluid cools, its volume reduces as cold hydraulic
fluid has a smaller volume than does hot hydraulic fluid. This causes
the cylinders on the boom, swing−out legs and supports to retract a
little and the boom and the support feet to sink.

Caution
The boom can sink during lengthy pauses in work due to cooling of
the hydraulic fluid. For this reason you should never leave the boom
in the unfolded position during breaks in working.
In addition, you must keep the supports under constant observation
whilst the machine is in operation. You may have to readjust the
swing−out cylinders and support cylinders.

Loss of volume

12300101

Sinking of the boom and the truck as a result of loss of volume

of the hydraulic fluid on cooling

The extent to which the boom and the truck sink depends on the
extent to which the various boom and support cylinders have been
extended and the magnitude of the temperature difference in the
hydraulic fluid.

556 MP07_075_0212EN
 Operation

5.5.5 Uncontrolled boom The following defects may be the cause of uncontrolled boom
movements movements:
− Malfunction in the remote control circuit
− Malfunction 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 for the breakdown
determined and rectified by qualified personnel.

Danger
In no event should you first press the EMERGENCY SHUT−DOWN
button if the boom starts uncontrolled movements. Should you do
this you will have no ability to counteract the movement.

MP07_075_0212EN 557
 Operation

Countermeasures You must proceed as follows if the boom starts uncontrolled

movement:

" 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 counter

measures:

" Press the EMERGENCY SHUT−DOWN button.

Note
Repeated practice is required to ensure that it will be possible to
implement the measures described above in an emergency.

558 MP07_075_0212EN
 Operation

5.6 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 section. 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 SHUT– Extend both arms outwards

DOWN and move up and down quickly.

10000308

Stop Extend both arms out to the

side.

10000306

Slow Place a fist on the helmet.

10000307

BP07_006_9508EN 559
 Operation

Slew boom to the left One arm points in the direction

of rotation.

10000309

Slew boom to the One arm points in the direction

right of rotation.

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

560 BP07_006_9508EN
 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_9508EN 561
 Operation

Arm 4 up One arm points upwards at an

angle. The other arm points up

wards 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

562 BP07_006_9508EN
 Operation

End hose forwards Move both crooked arms

forwards and backwards.
The palms of the hands face
inwards towards the person
giving directions.

10000321

End hose back Move both crooked arms

forwards and backwards.
The palms 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_9508EN 563
 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 pumping The thumb of one hand points

rate/start pumping upwards. The palm of the other
hand is held over it.

10000327

Reduce pumping rate The thumb of one hand points

downwards. The palm of the
other hand is held under it.

10000328

564 BP07_006_9508EN
 Operation

Reverse pumping The crooked bend 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_9508EN 565
 Operation

5.7 Extending the Proceed in the sequence specified to extend the 3Z boom. The
3 Z boom boom must be folded in the reverse sequence.

Caution
The hydraulic fluid is warm when you fold the arm assembly. It then
cools and the pressure in the cylinder drops. If you then raise arm1,
the remaining arms become depressurised and may fall down.

You must therefore draw the arm assembly together briefly before
raising arm1.

Take care when unfolding the boom or during boom operation, that
you do not damage the driver’s cab or other components. You may
need to raise arm1 even further.

566 MP07_041_0507EN
 Operation

5.7.1 End hose

MP07_041_0507EN 1

End hose retainer

" Withdraw the end hose from the end hose retainer.

5.7.2 Arm 1

45_

MP07_041_0507EN 2

Raise arm 1

" Raise arm 1 through approximately 45°.

MP07_041_0507EN 567
 Operation

5.7.3 Boom

180 °

MP07_041_0507EN 3

Slewing the placing boom

" Slew the placing boom through 180°.

5.7.4 Arm 2

MP07_041_0507EN 4

Raising arm 2

" Extend arm 2 approximately 45_so that it is pointing down

wards at an angle.

568 MP07_041_0507EN
 Operation

5.7.5 Arm 3

MP07_041_0507EN 5

Unfolding arm 3

" Unfold arm 3.

MP07_041_0507EN 6

Possible pumping position

" Carefully bring the end hose to the site of concrete placement.

MP07_041_0507EN 569
 Operation

5.7.6 Impermissible
working range

MP07_041_0507EN 7

1 Area in which work with the end hose is not permitted

Caution
The end hose must not be shifted behind the vertical of the boom.

570 MP07_041_0507EN
 Operation

5.8 Pumping operations You must carry out the following operations 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
machine" section).
− Carry out all necessary function checks (see Function checks"
section).
− Extend the boom to the desired working position (see Extending
the placing boom" section).

5.8.1 Hazards Dangers to the life and limb of site personnel can arise at many
points during pumping operations. You can minimize these dangers
by observing the following notes.

End hose striking out

2 12500500

1 End hose length, maximum 3 m

2 Danger zone = 2 × end hose length = 6 m

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 washing out. This zone is twice the end hose length
in diameter.
The end hose must be allowed to hang freely.
Ensure that no−one is standing in the danger zone. Keep the danger
zone under constant observation.
You must halt work immediately and press the EMERGENCY SHUT−
DOWN button if anyone enters the danger zone.

MP07_064_9912EN 571
 Operation

Incorrect use of the

endhose

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.

572 MP07_064_9912EN
 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.

MP07_064_9912EN 573
 Operation

5.8.2 Notes on correct To supplement the notes given here, you will find comprehensive
pumping information on the following subjects in our Concrete technology"
pamphlet (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 pamphlet 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. Calm pumping is achieved if the
rear wheels are in light contact with the ground. Do this by retracting
the rear support feet until the rear wheels are in ground contact and
then retract the support feet about another1cm.

If the support is correct, reduce the pump speed or change the

boom position.

The boom can also bounce if air is taken in and compressed in the
delivery line. You should therefore always make sure that the agitator
hopper is always filled with concrete to the mixer shaft and that no air
is sucked in.

574 BP07_321_9704EN
 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.

BP07_321_9704EN 575
 Operation

5.8.3 Starting pumping The process from the start of concrete pumping to the time at which
a continuously flowing stream of concrete exits from the end hose is
known as starting to pump.

The entire delivery line must be wetted with water at the start of
pumping operations.

" Run the rotor forwards.

" Spray approximately 10−15 litres of water into the intake cone.

" Allow the agitator to run in reverse.

" Swing the mixer chute away from the intake cone.

This ensures that no coarse grain is sucked in at the start of
pumping.

" Slowly fill the hopper with concrete and pump at medium
speed.

The process of starting to pump is completed when a solid stream of

concrete exits from the end hose.

" Switch the agitator over to forwards.

" Swing the mixer chute towards the intake cone.

Note
You must start to pump with a cement−water mixture (grout) if the
delivery line is new, if the concrete recipes are difficult or if the
delivery line has not been used for a long time.

576 MP07_023_9912EN
 Operation

5.8.4 Pumping Correct mixing of the concrete influences pumping performance.

Caution
The maximum delivery pressure shall not exceed that specified on
the rating plate or in the check book.

" 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 admix

tures) as required. Observe the mixing times specified by the
additive manufacturer.

" Pour the concrete from the truck mixer, silo, etc into the agitator
hopper.

" Switch the agitator on.

" Switch the pump on and begin pumping.

Note
Start with a low output and increase this gradually after several cubic
metres.

MP07_023_9912EN 577
 Operation

5.8.5 Breaks in pumping You should avoid breaks in pumping as far as possible, as the con

crete in the delivery line can start to set, or can become segregated
due the vibrations of the machine. Note the following points if breaks
are unavoidable:
− Never leave the delivery line under pressure;
− Relieve the delivery line during short breaks in delivery by reverse
pumping briefly. 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;
− Pump the concrete back into the agitator hopper before long
breaks in pumping. You must mix the concrete again before you
re−start 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.

578 MP07_023_9912EN
 Operation

5.8.6 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

No. 0 Designation
1 Wedged aggregate
2 Cement paste
3 Boundary layer

The following faults can lead to blockages:

− delivery line insufficiently wetted;
− lines leaking;
− concrete leavings in the delivery pipes;
− unfavourable concrete composition;
− segregated concrete;
− set concrete.

Note
Avoid blockages, this will extend the service life of the pump tube.
Ifthe pump tube is damaged, there may be concrete residue in the
rotor housing. In this case, you should read the Before starting"
section of the Operation" chapter.

Caution
In the event of blockages, pump the concrete immediately back into
the agitator hopper and mix it up. Then begin pumping again with
care.

MP07_024_0301EN 579
 Operation

Engine Do not exceed the permissible engine speed specified in the

machine card or on the rating plate on the machine. Always set the
engine speed higher than the vibrating speed. Do not switch the
engine off immediately after periods of heavy engine loading, but
first allow it to cool down while idling.

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 switched off automatically and a red indicator lamp lights up
on the control cabinet in the event of oil overheating over 90_ C.
Proceed as follows to prevent this:

" Reduce the output.

Note
The thermostatically regulated fan switches on at temperatures over
55_ C. It may also be switched on manually from the control cabinet.

Caution
If the fluid temperature exceeds 80_ C, you must trace the cause of
the overheating and rectify it. Do not switch the engine off, as the
radiator must remain in operation.

Never spray water on the hydraulic fluid reservoir. Damage may be

caused to the hydraulic pump.

580 MP07_024_0301EN
 Operation

5.8.7 Restarting Should the pump have, nevertheless, been switched off because of
overheating, you should proceed as follows:

" Switch the pump off.

" Never switch the engine off, as the radiator must remain in
operation.

" Look for the cause of fluid overheating and rectify it. Wait until
the fluid has cooled if you are not able to find the fault immedi

ately.

" 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.

MP07_024_0301EN 581
 Operation

5.8.8 Special cases On some construction sites, it may be the case that the net reach of
the boom is not adequate. You then have the option of connecting a
continuation delivery line to the boom tip or, if your machine is
equipped with a lateral outlet, connecting a delivery line there.

Continuation
delivery line

22202100

Connect continuation delivery line

Caution
No forces must be transferred from the fixed delivery line to the
boom or vice versa.

The stationary delivery line may not place additional loading on the
boom. This will prejudice the stability of the machine.

The delivery hose may not be bend, nor may be it be stretched.

Blockages can occur if it is bent. If it is stretched out, forces may be
transmitted which can lead to damage to the structure, delivery hose
or boom.

The boom can sink during pumping operations and place the deliv

ery hose under tension as a consequence of cooling of the hydraulic
fluid in the boom cylinders. This can cause forces to be transferred
or the delivery hose to tear. You should therefore keep the delivery
hose under constant observation.

582 BP07_325_9704EN
 Operation

" Extend the boom to bring the last arm approximately 1.5−2 m
from the stationary delivery line.

" Dismantle the end hose.

" Mount a 3 m long delivery hose in place of the end hose.

" Connect the delivery hose and the fixed delivery line using a
SKH attachment coupling. Use an A seal as the seal.

" Fasten the SKH attachment coupling securely to the structure.

BP07_325_9704EN 583
 Operation

5.9 Cleaning Concrete leavings that are deposited inside the delivery line or pump
unit can cause damage, will accumulate and reduce the cross−sec

tion. Therefore, it is essential that these parts are thoroughly rinsed if
you wish to be able to start pumping without difficulty on the next
job.

Cleaning instructions

Note
Only use cold water at a maximum water pressure of 5 bar for clean

ing all painted surfaces in the first four weeks of using the machine.
Do not use any aggressive cleaning agents. The paint is not fully
cured until after this period and you will then be able to use steam jet
equipment or other devices.

Never use sea water or other water containing salt for cleaning pur

poses. You must rinse off any sea water that gets on the machine.

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. Execute the machine functions required during cleaning
operations from the control cabinet.

584 MP07_060_0107EN
 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
possible.

We recommend that you use the Putzmeister Leavings sheet" to

allow you to make use of the concrete leavings. You can lay this
down under the hopper before opening the hopper flap. The
concrete then flows out into the sheet and can be transported to
thesite of concrete placement using a site crane.

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
concrete has cured, 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.

MP07_060_0107EN 585
 Operation

Danger
Leave the agitator grille closed during all cleaning operations, since
you could be trapped by the agitator.

The automatic agitator cut−out must operate if it is nevertheless

necessary to open the grille.

10800500

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 his supervision. Putzmeister accepts no lia

bility for damage caused by incorrect implementation of compressed
air cleaning. All persons participating in the cleaning operation must
be instructed in the safety regulations.

586 MP07_060_0107EN
 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

10003401

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.

MP07_027_9712EN 587
 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.

1 1

3
2
4

3 5

4 6
MP07_027_9712EN 1

Normal catch basket Catch basket for rotor pumps

1 Coupling 1 Coupling
2 Catch basket 2 Pressure dump bend
3 Spring pin (on both sides) 3 Pressure dump cock
4 Catch bracket 4 Catch basket
5 Spring pin (on both sides)
6 Catch bracket

588 MP07_027_9712EN
 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
31201503

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

MP07_027_9712EN 589
 Operation

Cement bags for Cement bags soaked in water and rolled up have proved useful
high−pressure when cleaning the delivery line using water under pressure. The
watercleaning cement bags prevent the washing water penetrating the concrete,
flushing the concrete out and causing blockages.

10003501

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.

10003502

590 MP07_027_9712EN
 Operation

5.9.1 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 591
 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

592 BP07_305_9701EN
 Operation

5.9.2 Suction cleaning of Suction cleaning is the simplest and least hazardous method of
the delivery line cleaning. It is described below.

" Pump the agitator hopper out until the concrete is level with the
top of the intake aperture.

" Then switch the pump off.

Insert the wash–out

sponge

MP07_029_9911EN 1

Inserting a water−soaked wash−out sponge

" Insert a water−soaked wash−out sponge (cube) into the end

hose outlet.

MP07_029_9911EN 593
 Operation

Shift the boom to a

rising position

MP07_029_9911EN 2

Suck the concrete from the top down the line

" Shift the placing boom into a uniformly rising position.

This makes it easier to pump the concrete back as the
concrete flows back under its own weight.

Caution
The rotor speed must not be greater than 20 rpm or 3s/revolution
during cleaning, as otherwise damage may be caused to the rotor.

" Switch the pump over to reverse pumping.

The concrete and the wash−out sponge are pumped back
through the delivery line.

" Switch the pump off as soon as the wash−out sponge arrives in
the hopper.

" Open the cover grille and remove the wash−out sponge.

" Repeat the washing out procedure, as a single reverse pump

ing pass of a wash−out sponge is not sufficient.

594 MP07_029_9911EN
 Operation

5.9.3 High–pressure High−pressure water cleaning, which is more thorough than suction
water cleaning cleaning, but requires more effort, is described below.

" Pump out the agitator hopper as far as possible.

Shift the boom to a

horizontal position

MP07_030_9911EN 1

Expelling the concrete to the front

" Shift the boom to a largely horizontal position to prevent the

concrete running back.

MP07_030_9911EN 595
 Operation

Drain off the leavings

40800100

Open the hopper flap

" Open the hopper flaps and remove the leavings from the
hopper.

" Spray out the hopper using a hose.

" Close the hopper flaps.

" Insert a water−soaked wash−out sponge (cube) into the intake

cone.

" Fill the agitator hopper with water.

596 MP07_030_9911EN
 Operation

Replace the end hose

with a catch basket

1 2

6
31201502

1 Coupling
2 Angle piece to vent compressed air downwards
3 Pressure dump cock
4 Catch basket
5 Spring pin (on both sides)
6 Catch bracket

" Remove the end hose and clean it separately later.

" Fit the catch basket illustrated above on the last delivery line
bend instead of the end hose.

" Close the shut−off valve on the catch basket.

MP07_030_9911EN 597
 Operation

Caution
The rotor speed must not be greater than 20 rpm or 3s/revolution
during cleaning, as otherwise damage may be caused to the rotor.

As soon as the wash−out sponge arrives in the catch basket, the

delivery line is sealed back to the hopper. This causes the pressure
in the delivery line to build. You must switch the rotor pump off
immediately the wash−out sponge arrives in the catch basket to
ensure that no damage is caused to the rotor pump.

" Switch the pump over to forwards pumping".

" Eject the concrete from the delivery line forwards.

Note
If one hopper−full is not sufficient, you will have to refill the hopper
with water before air is taken in. Continue pumping until the wash−
out sponge exits from the end hose. Take care to ensure that the
water flowing behind it does not run into the formwork.

" Keep the catch basket under observation and switch the pump
off as soon as the wash−out sponge arrives in the catch
basket.

598 MP07_030_9911EN
 Operation

Shift the boom to a

rising position

MP07_030_9911EN 2

Allowing the washing water to drain back

" Shift the placing boom into a uniformly rising position.

" Switch pump over to reverse pumping and suck the wash−out
sponge back through the delivery line.

" Repeat the washing out procedure to ensure that the delivery
line is metallically clean on the inside.

Caution
The delivery line, water tank and water pump must be drained fully if
there is a risk of freezing. Leave the water outlet open afterwards.

" Then remove the catch basket again and fit the cleaned end
hose.

MP07_030_9911EN 599
 Operation

5.9.4 Compressed air Pushing the concrete forwards out of the delivery line by letting the
cleaning rotor pump run slowly is the same as cleaning with compressed air.

Danger
There is an increased risk of accident when cleaning with com

pressed air. The cleaning operation must only be carried out as
described below by a subject expert or under his supervision.
Putzmeister accepts no liability for damage caused by incorrect im

plementation of compressed air cleaning. All persons participating in
the cleaning operation must be instructed in the safety regulations.
You must observe the following rules without fail when you use com

pressed air to clean out the delivery line:
 Single pipes and short pipe runs up to 10m in length must not be
blown through with air.
 No delivery hose or end hose may be fitted to the end of the deliv

ery line.
 A catch basket must be fitted to the end of the delivery line.
 The concrete must be able to escape freely from the end of the
delivery line.
 No persons may be present in the area 3m around the delivery
line, at the end of the delivery line and in particular in front of the
opening of the catch basket.
 The boom position must be selected such that any concrete that
might be forced out of the catch basket cannot injure any persons
or cause damage.
 The sponge ball or the plug used to force the concrete out must
be of sufficient diameter for the delivery line to be sealed to the
rear when the sponge ball or the plug is caught in the catch
basket.
 Only work on the delivery line once it has been depressurized.
 The pressure drain cock must be opened in such a way that
no−one can be injured by any leavings that might be ejected
fromthe dump cock.

5100 MP07_031_9912EN
 Operation

" Pump out the agitator hopper as far as possible.

Shift the boom to a

horizontal position

MP07_031_9912EN 1

Expelling the concrete to the front

" Shift the boom to a largely horizontal position to prevent the

concrete running back.

" Insert a medium hardness, water−soaked wash−out sponge

(cube) into the intake cone.

Note
The wash−out sponge can be damaged by the pressure rollers in the
rotor pump if the wash−out sponge runs slowly through the rotor
housing.
You should therefore hold the water−soaked wash−out sponge in
front of the intake cone until the wash−out sponge is sucked in vigor

ously by the vacuum in the rotor pump.

MP07_031_9912EN 5101
 Operation

Replace the end hose

with a catch basket

1 2

6
31201502

1 Coupling
2 Angle piece to vent compressed air downwards
3 Pressure dump cock
4 Catch basket
5 Spring pin (on both sides)
6 Catch bracket

" Remove the end hose and clean it separately later.

" Fit the catch basket illustrated above on the last delivery line
bend instead of the end hose.

" Close the shut−off valve on the catch basket.

5102 MP07_031_9912EN
 Operation

Caution
As soon as the wash−out sponge arrives in the catch basket, the
delivery line is sealed back to the hopper. This causes the pressure
in the delivery line to build. You must switch the rotor pump off
immediately the wash−out sponge arrives in the catch basket to
ensure that no damage is caused to the rotor pump.

Danger
No−one may be present around the catch basket during the washing
out operation as there is a risk of injury from ejected concrete.

There is a danger of concrete residues being expelled violently when

the dump cock is opened. You should therefore turn away when
opening the dump cock.

" Switch the pump over to forwards pumping".

" Eject the concrete from the delivery line forwards.

" Keep the catch basket under observation and switch the pump
off as soon as the wash−out sponge arrives in the catch
basket.

" Open the dump cocks on the catch basket and allow the
compressed air to vent.

" Switch pump over to reverse pumping and suck the wash−out
sponge back through the delivery line.

" Repeat the washing out procedure to ensure that the delivery
line is metallically clean on the inside.

" Then remove the catch basket again and fit the cleaned end
hose.

MP07_031_9912EN 5103
 Operation

5.9.5 Cleaning the hopper Concrete leavings that are deposited inside the pump tube can
and rotor pump cause damage, will accumulate and jeopardize the function of the
pump tube. For this reason, thorough flushing is required at the end
of a job, unless the next pumping job follows within 30−60minutes.

Drain off the leavings

40800100

Lay the sheet down

" Place the Putzmeister leavings sheet beneath the hopper.

Caution
You may only hoist a maximum of 0.5m 3 concrete (approxi

mately1200kg) using the Putzmeister leavings sheet.

" Open the hopper flaps beneath the hopper and let the leavings
flow out of the hopper.

5104 MP07_032_9911EN
 Operation

30000500

Hoisting the concrete away

" Hoist away the concrete in the Putzmeister leavings sheet.

" Spray out the hopper using a hose.

" Close the hopper flaps beneath the hopper and fill the hopper
half full with water.

" Start the rotor pump up and pump the water into the delivery
line and back 2−3times.

" Hose down all components that have come into contact with
concrete until the water runs clear.

MP07_032_9911EN 5105
 Operation

5.9.6 Truck superstructure Once the delivery line, hopper and pump unit have been washed
and post–washing out, you must then thoroughly rinse down all parts of the machine
operations that have come into contact with concrete. Concrete that is not
washed off immediately can attack the paint, especially if aggressive
concrete additives have been used.

Caution
The delivery line, water box, water tank and water pump must, inso

far as they are present, must be drained fully if there is a risk of
freezing. The water box must also be drained at normal tempera

tures during longer breaks in pumping, eg overnight and at week

ends, 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.

" Clean all seals and the seal seats. Grease the seals before
replacing them.

" Clean the remaining parts of the machine by rinsing down with
a water hose.

" Then spray the metal components with an anticorrosion agent

or release agent.

Note
Please also read the High−pressure water pump" section if your
machine is equipped with a high−pressure water pump.

5106 MP07_061_9910EN
 Operation

High–pressure The high−pressure water pump is used to wash the outside of the
water pump machine (e.g. painted surfaces) using pressurized water. Bleed the
high−pressure water pump before it is used and after it has been
drained.

Use only the following cleaning media:

− water up to a maximum temperature of 60°C
− commercial cleaning agents

Danger
Make sure that you are holding the gun and lance firmly in your hand
or that the gun is secured using a retainer before switching on the
high−pressure water pump.
Never point the gun at people or animals.
Never direct the water jet towards the electrical components of the
machine (e.g. control cabinet, electric motors).

Do not use flammable or explosive liquids (such as petrol or diesel)

in the high−pressure water pump. Failure to observe these safety
precautions may result in injury to people or damage to the high−
pressure water pump.

Make sure that the water system is depressurized and empty of

water before undertaking any repair work.

Note
Use the oil inspection glass to check the oil level in the high−pres

sure water pump before each use. If necessary, top up the oil.
0.3litres of oil with an oil viscosity conforming to SAE30 is required
to fill the oil reservoir completely.

The high−pressure water pump can only be switched on if the follow

ing switch−on conditions are fulfilled:
 power take−off is engaged,
 water tank is sufficiently full,
 shut−off valve is open.
The high−pressure water pump will switch off or cannot be switched
on if the water level drops below the level of the fill−level sensor.

BP07_588_0403EN 5107
 Operation

Water system

1
2 3

4 5 6 7 8 9 10 11

BP07_588_0403EN 1

No. 0 Designation
1 Shut−off valve
2 Air vent cock
3 High−pressure water pump
4 Water filter
5 Drain cock
6 Pressure gauge
7 Emergency operation
8 High−pressure hose
9 Gun
10 Lance
11 Spray nozzle

Caution
The high−pressure water pump is not suitable for pumping drinking
water or food.
The liquid drawn in must not contain sand or other solids in suspen

sion. Solid particles would affect pumping operations and may
damage components of the high−pressure water pump, e.g. seals
and pistons.

5108 BP07_588_0403EN
 Operation

Bleeding the Use the air vent cock to bleed the high−pressure water pump before
watersystem it is used and after it has been drained.

Danger
Wear protective goggles and protective clothing during high−
pressure cleaning.

" Make sure that there is sufficient water in the water tank and
that the water temperature is above 5°C.

" Disconnect the high−pressure hose at the quick−release

coupler on the high−pressure water pump.

" Open the shut−off valve on the intake water line to the tank.

" Open the air vent cock on the water filter housing to allow the
air to escape from the intake line.

" Close the air vent cock again as soon as water is flowing
steadily from the drain cock.

" Start up the truck engine and run it at idling speed.

" Switch on the high−pressure water pump.

The green indicator lamp on the control cabinet will light up
when the switch−on conditions are fulfilled.

" Allow the high−pressure water pump to run until the water flows
steadily from the hose connection.

" Switch off the high−pressure water pump.

BP07_588_0403EN 5109
 Operation

Using the high−pres
Follow the instructions listed below before using the high−pressure
sure water pump water pump:

Danger
Wear protective goggles and protective clothing during high−
pressure cleaning.

" Connect the high−pressure hose with the cleaning gun and
lance to the high−pressure water pump.

" Open the shut−off valve on the intake water line to the tank.

" Switch on the high−pressure water pump.

The green indicator lamp on the control cabinet will light up
when the switch−on conditions are fulfilled.

" Open the gun and keep it open until water flows steadily from
the spray nozzle and any air is completely vented from the
lines.

" With the gun open, increase the speed of the engine until the
pressure gauge on the high−pressure water pump shows an
operating pressure of 100bar.

" Close the gun again.

The high−pressure water pump automatically switches the
water system to depressurized circulation.

The pressure gauge must show a level between 0bar
and10bar.

" Repeat the procedure to test and inspect all parts and func

tions under pressure.

The high−pressure water pump is now ready for service.

" Do not direct the cleaning jet perpendicularly onto the surfaces
to be cleaned. Try to peel" the layer of dirt off the painted sur

face.

" Maintain a minimum clearance of 30cm between the cleaning

lance and the surface to be cleaned.

5110 BP07_588_0403EN
 Operation

After use and when After each use of the high−pressure water pump:
there is a risk of
freezing " Flush out the high−pressure cleaning system with water if you
have used a cleaning agent.

" Switch off the high−pressure water pump.

" Shut off the water supply.

You only need to drain the residual water from the high−pressure
water pump, even if the machine is working on a construction site,
ifthere is a risk of freezing.

" Open the air vent cock on the intake line and the drain cock on
the water filter and allow the water to drain out of the intake
line.

Danger
The pressure hose and the cleaning gun unions and quick−release
couplers may only be undone once the water system has been
depressurized.

" Relieve the high−pressure water pump by opening the gun.

Check whether the pressure gauge shows that there is
pressure remaining in the system. If this is the case, dump
thepressure in the water system completely.

" Disconnect the high−pressure hose at the quick−release

coupler on the high−pressure water pump.

Note
Only reconnect the water pump to the water supply shortly before
starting up the system again, checking that it has not even partially
frozen.
If the pump head freezes, you should preheat it with hot water for a
quarter of an hour.

BP07_588_0403EN 5111
 Operation

Note
If there is insufficient water supply, an emergency operation valve
prevents the high−pressure water pump from switching on. This en

sures that the high−pressure water pump is not inadvertently allowed
to run dry.

If you still wish to drain the high−pressure water pump, you must
manually override the emergency operation valve which is situated
close to the water pump lever or on the high−pressure water pump.

2 3

BP07_588_0403EN 2

No. 0 Designation
1 Manual emergency operation
2 Emergency operation valve
3 Electrical emergency operation

Caution
The high−pressure water pump may not run for more than 15seconds
without water. The pump will run dry and may be damaged if you
allow it to run for longer.

" Press the emergency operation button or switch.

The emergency operation valve is overridden and the
high−pressure water pump is switched on.

5112 BP07_588_0403EN
 Operation

" Allow the high−pressure water pump to run until water no

longer flows from the hose connection, but for a maximum
of15seconds.

" Switch off the high−pressure water pump.

" Switch off the engine only at this point.

" Disconnect the high−pressure hose from the gun.

" Press the trigger lever on the gun to drain the gun and the
high−pressure hose. Make sure that you direct the spray nozzle
upwards (to drain the cleaning gun more easily).

BP07_588_0403EN 5113
 Operation

5.10 Driving position Please also read the Driving, towing and loading" chapter.

Caution
Always observe the specified sequence for extending and retracting
the boom. Carefully retract the placing boom.

5.10.1 Shift the placing boom to the driving position

1
3 4
2

MP07_043_9905EN 1

Sequence for folding the boom

" Retract the boom arms beginning with arm 3. The procedure is
the reverse of the sequence for extending the boom. Push the
end hose into the end hose retainer.

Note
The arms must be fully retracted and lay on the mounts provided.
Check that the end hose is inserted in the end hose retainer.

5114 MP07_043_9905EN
 Operation

5.10.2 Retracting the The same safety and operational regulations apply for retracting 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.

MP07_063_9912EN 5115
 Operation

Danger of crushing
There is a danger of crushing in the swing−out 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 EMERGENCY SHUT−
DOWN button if anyone enters the danger zone.

5.10.3 Remote control

2

10504701

Preselection switch

" Switch the toggle switch on the remote control to

SupportsOn".

5116 MP07_063_9912EN
 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 front feet.

" Now swing the support legs in or retract them.

" Switch the toggle switch on the remote control to the

SupportsOff" position.

" Secure all the snaplocks with spring pins.

" Remove the remote control and lock it away in the driver’s cab.

" Switch off the power take−off.

" Secure the end hose and the accessories against falling from
the truck.

MP07_063_9912EN 5117
 6 Maintenance

In this chapter you will find information on maintenance work which is

necessary for the safe and efficient operation of the machine.

Following the general maintenance information, you will find the

maintenance cards necessary for this machine. The table of contents
includes a summary of the maintenance cards in numerical order,
you will find an alphabetical summary in the Index of key words
under the entry for Maintenance cards".

We should like here to emphasise expressly that all prescribed

checks, inspections and preventative maintenance work must be
conscientiously 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
assistance.

BP09_001_9405EN
 Maintenance

6.1 Maintenance intervals The following table shows the intervals for the various maintenance
tasks. The associated maintenance cards can be found further on in
this chapter.

Note
Have the first After Sales service after 50 hours of operation carried
out by a Putzmeister After Sales Service engineer. The machine op

erator responsible for the machine should be present for this service.

every ... hours of operation other

Assembly Action
daily 250 500 1000 1500 2000 intervals

Lubricate all lubrication points D weekly

Visual and function check on all

D
safety equipment
General Check threaded unions against
as required
torque 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)

depending
on fluid
Hydraulic system Full fluid change analysis
result or
annually

Clean fluid sump D

Check hydraulic cylinder for

monthly
tightness (visual inspection)

Clean hydraulic fluid cooler D D

Check contamination indicator on

D
the filters
Fluid filter Replace boom filter element as required

Replace suction filter element as required

Transfer gearbox full oil change D

Transmission Agitator gearbox full oil change D

Rotor gearbox full fluid change D annually

MP09_004_0402EN 61
 Maintenance

every ... hours of operation other

Assembly Action
daily 250 500 1000 1500 2000 intervals

Water tank Check water level D

Compressed air filter

D
inspectionglass

Replace/clean vacuum filter as required

Vacuum system
Check oil level D as required

Change the oil D as required

Check inspection glass D

Inspect roller gap as required

Check tightening torque of the

Rotor unit D as required
pressure roller clamping bolts

when
Lubricate both sides of the
replacing
pressure rollers
pump tube

Grease pump tube as required

Pump tube
Replace pump tube as required

Safety clips on couplings D as required

Delivery line
Check wall thickness D as required

Grease the mixer shaft bearings D

Hopper Function check on the agitator
D
cut−out

Parts in contact with concrete Wear check D

Centralized lubrication system Check grease level D

Truck engine
In accordance with the truck manufacturer’s maintenance information
Truck transmission

Caution
The pump tube will heat up if large volumes of concrete (>30m 3)
are delivered in one session. This heating causes the silicon grease
to drip from the pump tube. You must ensure that the pump tube is
always greased.

62 MP09_004_0402EN
 Maintenance

6.2 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 sections of the Operating Instructions or in
spare parts sheets.

Caution
You must always use bolts of the same size and grade when you have
to replace bolts. Bolts with adhesive in the locking threads and self−
locking nuts must always be replaced after removal.

The tables below give the maximum tightening torques Md in Nm

fora friction factor µtot. = 0.14, for a lightly−oiled or lightly−greased
thread.

Note
All tightening torques are multiplied by a factor of 1.1 for bolts with
cement in the thread.

BP09_003_9412EN 63
 Maintenance

Set screws – metric triangular thread DIN 13, Part 13

Dimensions Tightening torque
[mm] Md [Nm]
M SW 8.8 10.9 12.9
M 4 7 3.0 4.4 5.1
M 5 8 5.9 8.7 10
M 6 10 10 15 18
M 8 13 25 36 43
M 10 17 49 72 84
M 12 19 85 125 145
M 14 22 135 200 235
M 16 24 210 310 365
M 18 27 300 430 500
10000900
M 20 30 425 610 710
SW = Width across flats M 22 32 580 820 960
X X = Grade
X.X G d 8.8,
8 8 10.9,
10 9 12.9
12 9 M 24 36 730 1050 1220
M 27 41 1100 1550 1800
M 30 46 1450 2100 2450

Set screws – metric precision thread DIN 13, Part 13

Dimensions Tightening
[mm] torque Md [Nm]
M SW 8.8 10.9 12.9
M 8  1 13 27 39 46
M 10  1.25 17 52 76 90
M 12  1.25 19 93 135 160
M 12  1.5 19 89 130 155
M 14  1.5 22 145 215 255
M 16  1.5 24 225 330 390
M 18  1.5 27 340 485 570
M 20  1.5 30 475 680 790
10000900
M 22  1.5 32 630 900 1050
SW = Width across flats M 24  2 36 800 1150 1350
X X = Grade
X.X G d 8.8,
8 8 10.9,
10 9 12.9
12 9 M 27  2 41 1150 1650 1950
M 30  2 46 1650 2350 2750

64 BP09_003_9412EN
 Maintenance

6.2.1 Flared screwed joint, Every time the joint has been undone, the union nut must be tightened
reassembly securely, without the use of excessive force.

Flared screwed joints

External Md [Nm] External Md [Nm]
diameter/ diameter/
Type Type
6 L 20 18 L 120
8 L 40 20 S 250
L 55 25 S 400
12
S 80 30 S 500
15 L 70 38 S 800
16 S 130

Note
Hold threaded union spigot fast against turning with wrench.

10400100

Tightening flared screwed joint

6.2.2 Profiled ring joint, Every time the joint has been undone, the union nut should be tightened
reassembly again without excessive force to ensure that the joint is tight.

BP09_003_9412EN 65
 Maintenance

6.3 Functional fluids This section lists all the functional fluids used in your machine.

Caution
Never use hydraulic fluids or lubricants with additives such as
molybdenum. Such additives can attack the bearings.

6.3.1 Hydraulic fluid The hydraulic system is filled with:

− mineral hydraulic fluid (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 230litres 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.

66 MP09_006_0502EN
 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.

MP09_006_0502EN 67
 Maintenance

6.3.2 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.

6.3.3 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.

6.3.4 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.

68 MP09_006_0502EN
 Maintenance

6.4 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.

BP09_005_0409EN 69
 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.

610 BP09_005_0409EN
 Maintenance

6.4.1 Hydraulic fluids

Type Mineral oil Synthetic ester Aqueous solutions
Model HLP HEES HFC
Classification
DIN 51502
ISO 6743/0
Requirement
DIN 51524 Part 2  
ISO 6743 Part 4  
VDMA 24318 24568 24317/24320
Other   7th Luxembourg Report
Viscosities
DIN 51519
ISO 3448
2
mm /s ISO VG 46 46 46
Use
10_C to +90_C
10_C to +90_C
20_C to +60_C
Particular
 biodegrades quickly non−readily flammable
characteristics
Initial filling
Material no. 000171.007 239693.000 239879.002
BECHEM HYDROSTAR FUCHS HYDROTHERM
Manufacturer 
HEP46 46M
Changeover guidelines
VDMA  24569 24314

BP09_005_0409EN 611
 Maintenance

6.4.2 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 p
parts
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.

612 BP09_005_0409EN
 Maintenance

6.4.3 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_005_0409EN 613
 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_0209EN 615
616
 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 service intervals in the maintenance summary at the start of this
chapter.

See also the maintenance cards:

Filter change
Hoses

No special tools required.

Danger
Inspect the electrical cables particularly closely and carefully. There
is a danger of overvoltages from defective cables, particularly when
there is high air or ambient humidity. There is a danger of fire and
explosion through the formation of sparks when the machine is used
in a potentially explosive atmosphere.

WK00_001_9411EN 617
 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 func

tioning condition.

Electrical system You must have any damage found in the electrical system rectified
immediately by a qualified electrician.

" Check that all electrical connections are secure and free from
corrosion.

" Check that the electrical cables have no breaks.

" Check the insulation on the electrical cables.

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 vacuum filters must be
replaced if the displays are in the red range.
Maintenance card: Filter change

" Check the contamination indicators on the boom filters. The

filters are in order if the red button remains depressed. The
filter must be replaced if the red button pops out.
Maintenance card: Filter change

" Check the oil cooler for contamination and deposits.

" Check all hydraulic hoses for leaks.

Maintenance card: Hoses

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

618 WK00_001_9411EN
 Maintenancecard
01−004
Page 1 of 4

01–004 Rotor gearbox This maintenance card describes the full fluid change of the rotor
full fluid change gearbox on the following pumps: R61, R62 and R63. You will find
the maintenance intervals in the maintenance summary at the start of
this chapter.

No further maintenance cards required.

No special tools required.

Note
The gearbox fluid must be changed for the first time no later than
after the first 100operating hours. Every future change of gearbox
fluid must take place after every 500operating hours.

This requires 2.5litres of gearbox fluid complying with DIN 51517 −

CLP220.

Environmental protection
You must catch the used fluid and dispose of it in accordance with
regulations. Even biologically degradable fluids must be disposed of
separately from other waste.

WK01_004_0302EN 619
 Maintenancecard
01−004
Page 2 of 4

Draining off used

gearbox fluid

WK01_004_0302EN 1

No. 0 Designation
1 Ventilation
2 Drain opening

" Rotate the rotor slowly until one of the two screw plugs is point

ing directly downwards (6 o’ clock).

The second screw plug will then be pointing directly to one
side (3 o’ clock or 9 o’ clock)

" Place a suitable container under the drain opening to catch the
used gearbox fluid.

" Remove both the screw plugs from the openings and drain off
the gearbox fluid.

620 WK01_004_0302EN
 Maintenancecard
01−004
Page 3 of 4

Filling with new

gearbox fluid

WK01_004_0302EN 2

No. 0 Designation
1 Filler opening
2 Overflow (fluid level check)

" Rotate the rotor gearbox slowly through 90_ until one of the two
openings is pointing directly upwards (12 o’ clock).

The second opening will then be pointing directly to one
side (3 o’ clock or 9 o’ clock)

" Add new fluid via the filling opening (upper opening) until it
exits from the overflow (side opening).

" As soon as fluid ceases to flow out of the overflow, both open

ings can be closed again using the screw plugs.

WK01_004_0302EN 621
 Maintenancecard
01−004
Page 4 of 4

622 WK01_004_0302EN
 Maintenancecard
01−018
Page 1 of 4

01–018 Changing the oil in the This maintenance card describes how to check the oil level and
vacuum pump change the oil in the vacuum pump.

No further maintenance cards required.

No special tools required.

Vacuum pump
1

4 3 2

5 6 7

8
WK01_018_0308EN 1

No. 0 Designation
1 Oil filler plug
2 Oil inspection glass
3 Oil drain plug
4 Oil filter (not on model 0012, 0016)
5 Filter elements
6 Oil trap
7 Intake port with integrated check valve
8 Oil return line

WK01_018_0308EN 623
 Maintenancecard
01−018
Page 2 of 4

Checking the oil level The oil level in the vacuum pump must be checked regularly to
prevent failures of the vacuum system.

Note
Check the oil level regularly at the oil inspection glass. Note the
Min." and Max." markings next to the oil inspection glass. The oil
level must reach at least the middle of the oil inspection glass when
the vacuum pump is switched off. Only top up the oil when the
vacuum pump is switched off. Change the oil no later than after the
first 100operating hours. After this, the oil must be changed every
six months or 250operating hours.

According to DIN 51506 you will require the following oils:

 for temperatures>10°C: SAE 30
 for temperatures<10°C: SAE 10

Replace the oil filter (where fitted) during every other oil change, but
at least every six months.

" Check the oil level at the oil inspection glass.

Top up the oil where necessary.

624 WK01_018_0308EN
 Maintenancecard
01−018
Page 3 of 4

Changing the oil The oil in the vacuum pump must be changed regularly to prevent
failures of the vacuum system.

" Place a suitable container under the drain opening. Drain off
the oil at the oil drain plug while it is still at operating tempera

ture.

" Top up with new oil until the oil level is at least in the middle of
the oil inspection glass. Note the Min." and Max." markings.

Note
A milky emulsion will be created if water gets into the oil. If you
detect an emulsion of oil in the vacuum system, carry out a full oil
change.

Replace the filter elements in the oil trap after 500operating hours,
but at the latest when you observe oil mist or loss of oil.

If the vacuum pump is losing oil at the exhaust side, you must clean
the oil return line and the check valve.

If the performance of the vacuum pump begins to decline, you must

clean the filter screen on the intake port or replace it as required.

Environmental protection
Collect the used oil and dispose of it in accordance with regulations.
Even biologically degradable oils must be disposed of separately
from other waste.

WK01_018_0308EN 625
 Maintenancecard
01−018
Page 4 of 4

626 WK01_018_0308EN
 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.

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_9411EN 627
 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

628 WK03_001_9411EN
 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_9411EN 629
 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.

630 WK03_001_9411EN
 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_9411EN 631
 Maintenancecard
03−001
Page 6 of 6

632 WK03_001_9411EN
 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.

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_9411EN 633
 Maintenancecard
03−002
Page 2 of 2

634 WK03_002_9411EN
 Maintenancecard
04−012
Page 1 of 6

04–012 Changing the suction filter This maintenance card describes how to change the suction filter
element element. You will find the maintenance intervals in the maintenance
summary at the start of this chapter.

No further maintenance cards required.

No special tools required.

Note
Replace the filter element once the indicator on the vacuum meter is
in the red zone.

Cleanliness is of the utmost importance in the maintenance of hy

draulic systems. Prevent any type of dirt from entering the system.
Even small particles of dirt may cause valves to be scored, pumps
toseize and throttle and control bores to become blocked.

Hydraulic fluid barrels must stand for some time before the fluid is
removed from them. Never roll the barrels to where you will be draw

ing off the fluid. Clean bungs and filler lids as well as the area around
them before opening.

If possible, you should use a charging set to fill up the hydraulic

system. Never leave the reservoir lid open longer than necessary.

WK04_012_0308EN 635
 Maintenancecard
04−012
Page 2 of 6

Caution
Filter elements freely available on the market have too low a flow
rate. You must, therefore, only ever use original Putzmeister filter
elements in order to prevent damage to the machine.

You must never attempt to clean filter elements. These must always
be replaced.

Environmental protection
Dispose of used filter elements in accordance with the relevant
regulations.

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
The pressure accumulated in pressurized systems must be dumped.

" Secure the machine against being started by unauthorised

persons  if you have any key−operated switches, remove the
key and disconnect the supply voltage.

" Secure your work area and fix notices to the locked controls
and setting devices.

636 WK04_012_0308EN
 Maintenancecard
04−012
Page 3 of 6

Changing

1. 3

2.
4.
3.

WK04_012_0308EN 1

No. 0 Designation
1 Lid
2 Hexagon nut
3 Plug
4 Drain cock

WK04_012_0308EN 637
 Maintenancecard
04−012
Page 4 of 6

" Place a container under the drain cock (4) to allow you to catch
the escaping hydraulic fluid.

" Unscrew the hexagon nuts (2) as far as the stop and remove
the filter element without turning it to the stop [1.].

A shut−off valve automatically interrupts the hydraulic fluid
supply.

" Open the upper plug (3) to provide an air supply [2.].

" Open the drain cock (4) and allow the hydraulic fluid to run out
of the filter housing [3.].

" Turn the lid (1) anti−clockwise and remove the filter element
completely [4.].

638 WK04_012_0308EN
 Maintenancecard
04−012
Page 5 of 6

WK04_012_0308EN 2

No. 0 Designation
1 Hexagon nut
2 Filter element
3 Magnetic rod

" Unscrew the hexagon nut (1) from the magnetic rod (3).

" Turn the filter element (2) to the left and withdraw it from the
magnetic rod (3).

" Wipe the magnetic rod (3) lengthways with a clean rag.

Note
Before fitting new filter elements, you must check all O−rings and
other seals on the filter elements and replace them if damaged.

" Fit a new filter element and screw the hexagon nut (1) back on.

Environmental protection
Any hydraulic fluid which escapes must be disposed of in accord

ance with the relevant regulations.

WK04_012_0308EN 639
 Maintenancecard
04−012
Page 6 of 6

Correction dimension The filter element must be adjusted to the correct length so that the
filter element opens to the rear after the filter housing has been fitted.
Use the length (correction dimension) given on the spare parts
sheet. If no correction dimension is specified, the length of the filter
element is as designed.

Note
The correction dimension is measured from the lower edge of the lid
to the tip of the filter element.

10400401

K=Correction dimension

" Check and, if necessary, adjust the filter element to the correc

tion dimension.

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 thoroughly with a clean rag.

" Install a new filter element. The installation procedure is the

reverse of the procedure for removing a filter element.

640 WK04_012_0308EN
 Maintenancecard
04−013
Page 1 of 6

04–013 Changing the pressure filter This maintenance card describes how to change the pressure filter
element element. You will find the maintenance intervals in the maintenance
summary at the start of 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 from entering the system.
Even small particles of dirt may cause valves to be scored, pumps
toseize and throttle and control bores to become blocked.

Hydraulic fluid barrels must stand for some time before the fluid is
removed from them. Never roll the barrels to where you will be draw

ing off the fluid. Clean bungs and filler lids as well as the area around
them before opening.

If possible, you should use a charging set to fill up the hydraulic

system. Never leave the reservoir lid open longer than necessary.

WK04_013_0308EN 641
 Maintenancecard
04−013
Page 2 of 6

Caution
Filter elements freely available on the market have too low a flow
rate. You must, therefore, only ever use original Putzmeister filter
elements in order to prevent damage to the machine.

You must never attempt to clean filter elements. These must always
be replaced.

Environmental protection
Dispose of used filter elements in accordance with the relevant
regulations.

Preparation The following tasks must be carried out before changing the filter
element:

" Switch off the hydraulic pumps.

" Switch off the engine/motor.

" Dump the fluid pressure completely.

" Switch off the remote control.

Danger
The pressure accumulated in pressurized systems must be dumped.

" Secure the machine against being started by unauthorised

persons  if you have any key−operated switches, remove the
key and disconnect the supply voltage.

" Secure your work area and affix notices to the locked controls
and setting devices.

642 WK04_013_0308EN
 Maintenancecard
04−013
Page 3 of 6

Checking Replace the filter element if the red button on the contamination
indicator pops out again after being pressed in at operating
temperature.

WK04_013_0308EN 1

Checking and changing the pressure filter

" Bring the machine up to operating temperature (> 50° C).

" Set the maximum engine/motor speed.

" Press the red button on the pressure filter.

Note
The filter element is OK if the red button remains depressed.

The filter element must be replaced if the red button pops out again.

WK04_013_0308EN 643
 Maintenancecard
04−013
Page 4 of 6

Changing

WK04_013_0308EN 2

No. 0 Designation
1 Filter element
2 Filter housing

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.

644 WK04_013_0308EN
 Maintenancecard
04−013
Page 5 of 6

" Undo the filter housing (2) and remove the filter element (1).

" Clean the filter housing (2) thoroughly with a clean rag.

" Install a new filter element.

Note
Before you fit new filter elements, you must check all O−rings and
other seals on the filter elements and replace them if damaged.

" Screw the filter housing back on and tighten it finger−tight.

" Then loosen the filter housing again by 1/4of a turn.

Note
If the filter housing remains screwed in to the stop, the precision
thread could deform slightly, which could cause difficulties the next
time the filter is changed.

Check the level of the contamination indicator. Always refit the pro

tective lid on the contamination indicator each time this is checked.

WK04_013_0308EN 645
 Maintenancecard
04−013
Page 6 of 6

646 WK04_013_0308EN
 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.

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_0308EN 647
 Maintenancecard
04−014
Page 2 of 4

8
1
7
6

2 3 4 5

WK04_014_0308EN 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)

648 WK04_014_0308EN
 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.

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_0308EN 649
 Maintenancecard
04−014
Page 4 of 4

650 WK04_014_0308EN
 Maintenancecard
04−002
Page 1 of 4

04–002 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.

No further maintenance cards required.

No special tools required.

Note
Check all hoses (including hose fittings) with the machine running.
You must replace the hoses at the slightest sign of damage or even
mere indications of threatened damage.

Leaking hoses

10400800

Check hydraulic hoses

Dark and moist patches on the fitting are external signs of incipient
damage. Check:
− the hoses for kinks, cracks or a porous surface and
− whether the hoses have been laid without restrictions.

Note
Beware of strong sunlight, the action of heat and the effects of
chemicals.

WK04_002_0305EN 651
 Maintenancecard
04−002
Page 2 of 4

Flared screwed joints

10400100

Tighten until there is a clearly perceptible increase in force

" Check whether the flared screwed joints are tight.

Note
You may only tighten leaking flared screwed joints with the permitted
torque. Tighten the joint until you clearly feel an increase in the force
required if you do not have a torque wrench available. You must
replace these flared screwed joints if leaking continues.

Flared screwed joints

External Type Max. torque External Type Max. torque
diameter Md [Nm] diameter Md [Nm]
6 L 20 18 L 120
8 L 40 20 S 250
L 55 25 S 400
12
S 80 30 S 500
15 L 70 38 S 800
16 S 130

652 WK04_002_0305EN
 Maintenancecard
04−002
Page 3 of 4

Replacing hoses The procedure for replacing hoses is as follows:

" Shut down the machine and secure against unauthorized

starting.

" Fully dump any (residual) pressure in the hydraulic system.

Danger
Hydraulic hoses may be mechanically pre−stressed. There is a risk
of injury from whipping hoses.

" Take care when undoing the joints.

" Close the connection points with a plug immediately you have
removed the old hoses. No dirt may enter the hydraulic circuit
and the hydraulic circuit must not run empty.

Danger
Hoses should not be more than six years old, including a storage
time of two years. Take note of the date of manufacture on the hoses.

" Keep the hoses free from dirt.

" Fit the hoses to be free from bends or points of abrasion.

" Bleed the hydraulic system.

" Carry out a test run and inspect all hoses again after fitting new
hoses.

Environmental protection
Catch escaping fluid in a container and dispose of in an environmen

tally friendly manner.

WK04_002_0305EN 653
 Maintenancecard
04−002
Page 4 of 4

654 WK04_002_0305EN
 Maintenancecard
04−005
Page 1 of 2

04–005 Vacuum meter This maintenance card describes how to replace the vacuum meter
and how to remove the packing piece. You will find the service inter

vals in the maintenance summary at the start of this section.

No further maintenance cards required.

No special tools required.

Note
Replace the vacuum meter if it is mechanically damaged or if the
display is incorrect, e.g. there is an indication although the machine
is not running.

Caution
You must remove or open the packing piece once you have fitted the
new vacuum meter.

WK04_005_9501EN 655
 Maintenancecard
04−005
Page 2 of 2

" Unscrew the old vacuum meter from the vacuum filter.

" Screw the new vacuum meter onto the vacuum filter.

10402000

Venting the vacuum meter

" Open the vent by either cutting off the tip of the packing piece
or piercing the rubber stopper, depending on the design.

656 WK04_005_9501EN
 Maintenancecard
06−004
Page 1 of 4

06–004 Adjusting the This maintenance card describes how to adjust the pressure rollers.
pressure rollers The distance between the pressure rollers and the tube bearing
surface in the rotor housing must always be set precisely to the gap
specified. You will find the maintenance intervals in the maintenance
summary at the start of this chapter.

No further maintenance cards required.

The following special tools are required:

Pressure roller setting gauge, part number 295973.007

Note
If the gap is too great, the pump tube is not compressed completely
and a sand blasting effect" may be set up, severely abrading the
inner surface of the pump tube.

If the gap is too small, the pump tube is squeezed too heavily. The
steel fabric in the pump tube is bent too far and can break.

You can test the gap without dismantling the rotor pump by means
ofa sponge ball test". This is done by forcing a medium hardness
sponge ball through the delivery line in the direction of pumping. If
the gap is too great, air will be heard escaping from the pump tube
and the sponge ball will exit the delivery line under no pressure.

WK06_004_0302EN 657
 Maintenancecard
06−004
Page 2 of 4

1 2 3

WK06_004_0302EN 1

No. 0 Designation
1 Hexagon head bolt
2 Inspection cover
3 Pressure roller adjuster

" Run the rotor slowly until the pressure roller adjuster(3)
appears centred behind the inspection cover(2) over the
lowerassembly opening.

" Open the ventilation cock on the rotor housing to dump the
vacuum within the rotor housing.

" Shut the machine down.

" Undo the hexagon head bolts(1) and remove the inspection
cover(2).

" Repeat this process for the inspection cover on the rear of the
housing.

The pressure roller is now accessible for adjustment from
both sides.

658 WK06_004_0302EN
 Maintenancecard
06−004
Page 3 of 4

1 1

WK06_004_0302EN 2

No. 0 Designation
1 Adjusting nuts
2 Vernier
3 Pressure roller clamping bolt

" Undo the clamping bolts for the pressure roller axles(3) on
both sides.

" Undo the adjusting nuts(1).

Note
The pump tubes may be of different diameter. The gap specified is
therefore an average value. The following deviating settings (see
table) may therefore be necessary. You should also check the gap
with a water pressure test.

Maintenance card: Water pressure test on the rotor pump

Tube circumference Gap

520 − 523 mm 34 mm
523 − 527 mm 35 mm
527 − 530 mm 36 mm

" Set the gap to an average value of 35mm using the two adjust

ing nuts(1).

WK06_004_0302EN 659
 Maintenancecard
06−004
Page 4 of 4

" Use the gauge supplied for setting the pressure rollers to
check the gap. Readjust the gap if necessary.

" Check on the vernier(2) that the pressure rollers are parallel.

Note
The distance changes by 1mm for every 4/6 turn.

" Lock the settings using the two adjusting nuts(1).

" Tighten the clamping bolts for the pressure roller axles(3)
again.

" Proceed in the same way for the second pressure roller.

Note
Make sure that the inspection cover gaskets are clean and properly
inserted in the inspection covers.

" Refit the inspection covers over the assembly openings.

660 WK06_004_0302EN
 Maintenancecard
06−029
Page 1 of 2

06–029 Water pressure test This maintenance card describes the water pressure test on a rotor
on the rotor pump pump. You will find the maintenance intervals in the maintenance
summary at the start of this chapter.

See also the maintenance cards:

Adjusting the pressure rollers

The following special tools are required:

Measuring flange, part number 254198.001
(cover with ball valve, hose, water pressure gauge)

10601300

Measuring flange, part number 254198.001

WK06_029_0002EN 661
 Maintenancecard
06−029
Page 2 of 2

" Fit the measuring flange to the delivery line bend after the
pump.

" Fill the hopper with water and put the hose of the measuring
flange in the hopper.

" Open the ball valve.

" Switch the rotor on and let it run at approximately 3 rpm or

20seconds/rev.

Note
The pump tube will be vented after a few revolutions. You will see
this by the fact that no more air bubbles are escaping from the end
of the tube inserted in the hopper.

" Close the ball valve.

Note
The water pressure must be the same at the pressure gauge for the
two pressure rollers. It should be approximately 10 − 12 bar.
Maintenance card: Adjusting the pressure rollers

" Then drain the hopper and refit the delivery line.

" Once the hopper is empty, push a water−soaked wash−out

sponge into the intake cone and push it briskly through the
delivery line.

Note
If the sponge ball does not reach the end hose, you must reduce the
gap on both pressure rollers by 1mm each (4/6 turns of the adjust

ing nuts).
Maintenance card: Adjusting the pressure rollers

" Continue the sponge ball test and repeat it once more.

662 WK06_029_0002EN
 Maintenancecard
06−030
Page 1 of 8

06–030 Replacing the pump tube This maintenance card describes how to replace the pump tube in a
rotor pump. You will find the maintenance intervals in the maintenance
summary at the start of the chapter.

See also the maintenance cards:

Adjusting the pressure rollers
Adjusting the hopper on rotor pumps
Water pressure test on the rotor pump

No special tools required.

Caution
Extreme demands are made on the pump tube. Use only original
Putzmeister pump tubes as replacements to ensure a long service
life.

Lubricate the pressure rollers before fitting the new pump tube. The
lubrication nipples are on the front and reverse of the pressure
rollers.

WK06_030_0308EN 663
 Maintenancecard
06−030
Page 2 of 8

Changing the rotor

pump’s direction of
rotation

WK06_030_0308EN 1

Direction of rotation of the rotor pump and the pressure rollers

Note
To change the pump tube, you will have to draw the old pump tube
out of the rotor pump and draw the new pump tube into the rotor
pump.
You can use the rotor pump’s rotating movement to do this. The
pressure rollers roll over the pump tube in the opposite direction
tothe direction of rotation of the rotor.
If necessary, change the direction of rotation of the rotor pump to
allow you to draw the pump tube in or out completely.

Danger
Risk of injury by crushing and shearing caused by moving machine
parts.
Never reach into the rotor pump assembly opening when the pump
is in operation.
Do not place any object or tools in the rotor pump assembly opening
when the pump is in operation. These objects may be trapped by the
rotor and become entangled in it. They might then hit you or be torn
from your hands and cause you injury.

664 WK06_030_0308EN
 Maintenancecard
06−030
Page 3 of 8

Removing the
pump tube 2
1

3 4
WK06_030_0308EN 2

No. 0 Designation
1 Pump tube
2 Coupling clamp (delivery side)
3 Coupling clamp (intake side)
4 Intake cone

" Open the ventilation cock on the rotor housing to vent the rotor
housing.

" Open and remove the coupling clamp(3).

" Open the coupling clamp(2) and remove the delivery line
downstream of the pump.

" Switch the rotor to reverse pumping at a slow speed.

" Pull the pump tube (1) off the intake cone(4) of the hopper.

The pump tube is drawn into the rotor housing from the
intake cone in reverse pumping.

" Change the rotor pump’s direction of rotation so that the

pumptube is pushed out of the rotor housing completely.

" Remove the coupling nipple from the pump tube at the
coupling clamp(2).

WK06_030_0308EN 665
 Maintenancecard
06−030
Page 4 of 8

Lubricating the
pressure rollers

WK06_030_0308EN 3

Lubrication nipples

" To lubricate the pressure rollers, turn them to the position of the
assembly opening.

" Remove the inspection cover.

666 WK06_030_0308EN
 Maintenancecard
06−030
Page 5 of 8

1 2
WK06_030_0308EN 4

No. 0 Designation
1 Lubrication nipple
2 Pressure roller

" Turn the pressure roller (2) until the lubrication nipple(1) can
be seen in the assembly opening.

" Lubricate the pressure roller on both sides.

" Replace the inspection cover.

" To lubricate the second pressure roller, turn the rotor 180° to
the assembly opening position.

" Remove the inspection cover.

" Turn the pressure roller (2) until the lubrication nipple(1) can
be seen in the assembly opening.

" Lubricate the pressure roller on both sides.

Caution
Lubricate the pressure rollers before fitting the new pump tube. The
lubrication nipples are on the front and reverse of the pressure
rollers.

WK06_030_0308EN 667
 Maintenancecard
06−030
Page 6 of 8

Fitting the pump tube Inspect and clean the tube bearing surface in the rotor housing
before you fit the new pump tube.

Note
Concrete residue or other unevenness on the tube bearing surface in
the rotor housing can lead to considerable problems in delivery and
reduce the service life of the pump tube.

" Check the distance between the pressure rollers and the tube
bearing surface in the rotor housing (gap).

Maintenance card: Adjusting the pressure rollers

" Grease the tube bearing surface in the rotor housing and the
new pump tube with silicon grease 704.

" Insert the coupling nipple in the upper end of the tube and
secure it with the coupling clamp.

" Undo and remove the hopper fastening bolts. Push the hopper
towards the rotor housing and secure the hopper with one bolt.

Caution
The rotor housing must be dry. Check the rotor housing thoroughly
for moisture (residual water, condensate water). Clean the rotor
housing if necessary.

Note
Clean the assembly surfaces thoroughly before reinstalling the
inspection cover. The inspection cover must be closed so that it is
vacuum tight.

" Replace the inspection cover.

668 WK06_030_0308EN
 Maintenancecard
06−030
Page 7 of 8

" Move the rotor to the position shown.

WK06_030_0308EN 5

Inserting the new pump tube

" Switch the rotor to reverse pumping at a slow speed.

The pump tube is drawn into the rotor housing in reverse
pumping.

" Change the rotor pump’s direction of rotation so that the

pumptube is drawn completely through the rotor housing
tothe intake cone.

" Switch the rotor pump off once you have pushed the lower end
of thepump tube up to the stop on the hopper intake cone.

" Fit the coupling clamp (intake side).

WK06_030_0308EN 669
 Maintenancecard
06−030
Page 8 of 8

Note
Only fit the delivery line bend once you have adjusted the hopper.

" Readjust the hopper.

Maintenance card: Adjusting the hopper on rotor pumps

" Carry out a water pressure test.

Maintenance card: Water pressure test on the rotor pump

Note
A new pump tube stretches during pumping operations. You should
therefore check the pump tube after approximately 50m 3 of concrete
have been delivered. Readjust the hopper if necessary.

Maintenance card: Adjusting the hopper on rotor pumps

Lubricate the surface of the tube with silicon grease 704 at short in

tervals with a low pumping volume of no more than50m 3 after fitting
a new pump tube. The grease may be applied at greater intervals as
operating hours increase at a maximum pumped volume of150m 3.

670 WK06_030_0308EN
 Maintenancecard
08−010
Page 1 of 4

08–010 Adjusting the hopper This maintenance card describes how to adjust the hopper after
on rotor pumps replacing the pump tube. You will find the maintenance intervals in
the maintenance summary at the start of this chapter.

No further maintenance cards required.

No special tools required.

Note
Clean the hopper and the mounting rails with the fastening bolts.
Concrete residue and other dirt can make the hopper difficult to
move on the mounting rail when the fastening bolts have been
removed.

WK08_010_0002EN 671
 Maintenancecard
08−010
Page 2 of 4

1 2

5 4 3
WK08_010_0002EN 1

No 0 Designation
1 Coupling clamp
2 Delivery line bend
3 Mounting rail
4 Fastening bolts
5 Hopper

" Undo and remove the fastening bolts(4).

" Run the rotor forwards slowly.

" Push the hopper(5) along the mounting rail(3) so that the
coupling nipple in the new pump tube butts up against the
coupling clamp(1).

" Connect the pump tube to the delivery line bend(2) at the
coupling clamp(1).

" Lock the hopper(5) in this position using the fastening

bolts(4).

" Let the rotor run for a few revolutions.

" Switch the rotor off when the pressure rollers are vertical in the
rotor housing.

672 WK08_010_0002EN
 Maintenancecard
08−010
Page 3 of 4

1 2 3

WK08_010_0002EN 2

1 Tube bearing surface in the rotor housing

2 Pump tube
3 Sliding shoe

Note
The pump tube(2) is in the correct position when the distance
between the pump tube and the tube bearing surface in the rotor
housing(1) is twice the distance between the pump tube and the
sliding shoe(3).

If the pump tube is too close to the tube bearing surface in the rotor
housing:

" Push the hopper along the mounting rail 1−2 holes away from
the rotor housing.

If the pump tube is too close to the sliding shoe:

" Push the hopper along the mounting rail 1−2 holes towards the
rotor housing.

WK08_010_0002EN 673
 Maintenancecard
08−010
Page 4 of 4

Inspect the pump tube for correct position in the rotor housing at
regular intervals. We recommend:
− After a pump tube change, until 500m3 of concrete have been
delivered, at least every 100m3.
− Once 500m3 of concrete have been delivered with the pump
tube, every 300m3.

674 WK08_010_0002EN
 Maintenancecard
10−005
Page 1 of 4

10–005 Measuring the wall This maintenance card describes how to measure the wall thickness
thickness (Machines of delivery lines. You will find the maintenance intervals in the main

without transfer tube) tenance summary at the start of this chapter.

No further maintenance cards required.

The following special tools are required:

Wall thickness measuring device

Note
Delivery lines are subject to constant wear. Measurement of the wall
thickness is particularly important before starting on major contracts.
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 the right concrete
pressure if the wall thickness of the delivery line has decreased
below the minimum required, particularly if a blockage has built up.

Caution
Only tap the delivery line with a piece of hardwood (hammer handle).
Otherwise, dents may be created and these will lead to more rapid
wear. In addition, the hardened layer of high wear resisting pipes
may flake off the inside of the pipe. The pipe can burst at points that
have suffered heavy wear.

WK10_005_9405EN 675
 Maintenancecard
10−005
Page 2 of 4

11000101

Tapping the delivery line with a hammer handle

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

Delivery line bends Uniform wear can be achieved by regularly rotating the delivery line
bends through 180°. The wear on the external radius of an elbow is
greater than that on the internal radius or on straight pipes. You
should, therefore, take special care when measuring the wall thick

ness of the external radius of an elbow.
The minimum wall thickness for bends is shown in the graph below.

11000200

676 WK10_005_9405EN
 Maintenancecard
10−005
Page 3 of 4

Measuring Follow the operating instructions supplied with the measuring device
when carrying out measurements. Do not measure the wall thickness
of the delivery line at just one point, but around the entire circum

ference of the delivery pipes.
The minimum wall thickness is shown in the graph below.

Caution
Pipes and elbows must be replaced as soon as the wall thickness
has declined to the value for the minimum wall thickness.
Putzmeister accepts no liability if the wall thickness is less than the
minimum wall thickness.

Note
As a rule it is possible to continue pumping with a concrete pressure
lower than that shown in the graph.

We should, however, draw your attention to the fact that the delivery
line is subject to varying loading as a result of the dynamic loading
during pumping. There is no general method for calculating the mini

mum wall thickness for this loading, which depends on the individual
circumstances, and so the delivery line can also burst at a concrete
pressure which is assumed still to be permissible.

Furthermore, the concrete pressure can rise to 85 bar in the event

ofblockages, meaning that the wall thickness will no longer be
adequate and the delivery line will burst.

WK10_005_9405EN 677
 Maintenancecard
10−005
Page 4 of 4

Graph Minimum wall thickness as a function of concrete pressure

[bar] 150

140

130

120

110

100

90

1
80

70

60

50

40

30

20

10

0
0,0 0,5 1,0 1,5 2,0 2,5 3,0 3,5 4,0 4,5 5,0
[mm]
1 Maximum concrete pressure

678 WK10_005_9405EN
 Maintenancecard
12−003
Page 1 of 2

12–003 High–pressure water pump This maintenance card describes the procedure for cleaning the
high−pressure water pump.

No further maintenance cards required.

No special tools required.

Caution
Make sure that the high−pressure water pump is depressurized and
empty of water before undertaking any maintenance work.
Check whether the pressure gauge shows that there is no pressure
in the high−pressure water pump. Dump the pressure in the high−
pressure hose by operating the gun.

Danger
Check all quick−release unions and quick−release couplers regularly
for tightness and leaks. No air may enter the system. There is a risk
of severe water hammer.
Check the high−pressure hoses for damage or wear.
You must carry out a thorough inspection of the water system on a
regular basis.

Note
Use the oil inspection glass to check the oil level in the high−pres

sure water pump before each use. If necessary, top up the oil.
0.3litres of oil with an oil viscosity conforming to SAE30 is required
to fill the oil reservoir completely.

Carry out the first oil change after approximately 50 operating hours
and then after every 500 operating hours.

WK12_003_0403EN 679
 Maintenancecard
12−003
Page 2 of 2

Cleaning the screen You must wash the screen in the water filter at least once a week.

1 2 3

WK12_003_0403EN 1

No. 0 Designation
1 Water filter housing
2 Screen
3 Lid

Caution
Always replace a damaged screen. The high−pressure water pump
must always have the full water supply.

" Unscrew the water filter lid.

" Withdraw the screen and clean it.

Caution
Make sure that the screen is fitted centrally. Do not use force when
screwing in the screen.

" Replace the screen and screw the lid back on the water filter.

680 WK12_003_0403EN
 Maintenancecard
20−034
Page 1 of 2

20–034 Lubricating the placing This maintenance card describes the lubrication of all lubrication
boom (TMM 24/TMM 26) 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 60 hours, unless a
different interval is specified. You should apply the grease until you
can see it escaping.

D D D D D D D D
D

D D D D D D D D

WK20_034_9906EN 1

Lubrication diagram for TMM24/TMM26 placing boom

WK20_034_9906EN 681
 Maintenancecard
20−034
Page 2 of 2

682 WK20_034_9906EN
 Maintenancecard
21−039
Page 1 of 2

21–039 Lubricating the boom This maintenance card describes the lubrication of all lubrication
pedestal (TR 27) 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.

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
escaping.

WK21_039_9906EN 1

Lubrication diagram for TR27 boom pedestal

WK21_039_9906EN 683
 Maintenancecard
21−039
Page 2 of 2

684 WK21_039_9906EN
 Maintenancecard
25−001
Page 1 of 8

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.

See also the maintenance cards:

Measuring the wall thickness

The following special tools are required:

4mm feeler gauge

General The delivery line is subdivided into two sections:

− Boom delivery line
− Pump−boom delivery line.

These comprise:
− bends;
− straight pipes of uniform length (maximum 3 m);
− adapter pipes (straight pipes manufactured individually for each
arm package in order to fit the delivery line to the arm lengths).

Wall thickness Measure the wall thickness of the delivery line to determine which
pipe sections need to be replaced.
Maintenance card: Measuring the wall thickness

The starting points for laying the pipe on the boom are the hinge
pivot points. The straight sections of the delivery line run from pivot
point to pivot point. 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.

WK25_001_9704EN 685
 Maintenancecard
25−001
Page 2 of 8

Adapter pipe length

plate

5
1

6
2

4
7

22500101

1 First adapter pipe on A arm (L1)

2 Second adapter pipe on A arm (L1.1)
3 First adapter pipe on B arm (L2)
4 Second adapter pipe on B arm (L2.1), etc.
5 First pipe in pump − boom delivery line (V1)
6 Second pipe in pump − boom delivery line (V2), etc.
7 V8 and V9 are adapter pipes for lateral outlets
8 V10 is always the riser pipe

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
pipes plate next to the rating plate or from the following spare parts
sheets:
− Boom delivery line: Spare parts sheet group 25.0
− Pump−boom delivery line: Spare parts sheet group 25.3

12501000

The adapter pipe lengths plate is located on the boom

686 WK25_001_9704EN
 Maintenancecard
25−001
Page 3 of 8

When ordering adapter pipes you should always state:

− Machine number Example: 22/.....
− Mounting position L3.1
− Length in mm 1377 mm
− Diameter DN DN 125

Caution
You must not exceed the delivery line wall thickness specified on
therating plate and in the machine card. The additional weight can
impair the machine’s stability.

Note
Should you wish to re−equip your machine to a delivery line of
greater wall thickness, the machine’s stability will have to be
recalculated and checked and approved by an authorized inspector.

Untensioned The boom delivery line must be fitted with the arm assembly fully
assembly relieved of tension:
− the arm assembly is not under tension in the transport position if
each arm is lying freely on the rest provided for this purpose;
− the arm assembly is not under tension when unfolded if each arm
is supported.

Caution
If the tension on the arm package is not fully relieved during
assembly, stresses may occur in the delivery line on movement of
the placing boom and consequential damage may be caused to the
pipe brackets and to the placing boom. Furthermore, the boom may
swing up and down causing the end hose to swing and strike out
during pumping operations.

WK25_001_9704EN 687
 Maintenancecard
25−001
Page 4 of 8

Clearance A clearance of 4 mm must be maintained between the delivery pipes

over the whole of the delivery line, so that the welding neck rings can
butt against the couplings without play. This clearance is achieved
either:
− automatically, through the use of a C seal (triple−lip seal), or
− manually, by adjustment, using a feeler gauge.

Seal C seals (triple−lip seals) are used where the delivery line runs in a
straight line and there is no rotational movement. The 4 mm clear

ance is created automatically.

Caution
No triple−lip seals (C seals) may be used in the pivot joints in the pipe
bends.

A seals are used:

− if the delivery line does not run in a straight line;
− in the pivot joints; and
− at the assembly coupling at the tip of the boom.
The spacing of 4 mm must be set using the feeler gauge.

Coupling Couplings with lever closures must be secured with a spring clip.

11000800

Securing couplings with lever closures

Couplings with a threaded closure are closed using self−locking

nuts. These nuts may not be re−used, but must be replaced each
time the coupling is fitted.

688 WK25_001_9704EN
 Maintenancecard
25−001
Page 5 of 8

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 clearance 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.

WK25_001_9704EN 689
 Maintenancecard
25−001
Page 6 of 8

Caution
No triple−lip seals (C seals) may be used in the pivot joints.

Fitting a C seal

4mm

11000302

The spacing is created automatically by the ring seal

" Push the C seal over the welded−on ring of the fixed delivery
line pipe.

" Lay the pipe to be attached in the pipe bracket and push it up
to the fixed pipe.

" Push the pipe to be attached as far as the stop in the ring seal.

" Fix the pipe to be attached in the pipe brackets.

" Fit the coupling and secure it.

690 WK25_001_9704EN
 Maintenancecard
25−001
Page 7 of 8

Boom delivery line The starting points for laying the pipe on the boom are the pivot
points.

" Grease all couplings and seals well internally before assembly.

Note
Use a multipurpose grease based on lithium soap marked K2K.

" Install the bends in the fitting couplings at the pivot points.

" Align the bends such that the straight pipes can be connected
without tension.

" Fix the bends.

" Install the fixed length delivery pipes.

" Install the adapter pipes last.

WK25_001_9704EN 691
 Maintenancecard
25−001
Page 8 of 8

Pump–boom The pressure pipe is the starting point for assembly.

delivery line
Note
You should use only high−pressure pipes when replacing these
delivery 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 multipurpose grease based on lithium soap marked 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 turn either.

" Fit the boom connection pipes as far as the bend on the riser
pipe.

692 WK25_001_9704EN
 7 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 Breaks in pumping, 5
78
Abbreviations, G
15
Adjusting the hopper, On rotor
pumps, 6
71
After Sales Service personnel, Defini-
tion of terms, 2
3
Agitator gearbox, Transmission oil,
6
12
Agitator hopper, Pumping operations,
5
73
Agitator safety cutout, 3
68

Inspection, 5
42
Antennae, Radio, telephone etc., 3
61
Arm assembly, Definition of terms,
2
1
Authorized inspector, Definition of
terms, 2
3
Auxiliary personnel, Definition of
terms, 2
2
B
Delivery line, 5
91, 5
93, 5
95, 5
100
Base structure, Definition of terms,
2
1
Blockages, 2
38
Boom

Bounce, 5
74

Description of the functions, 3
13

Favourable boom position, 5
75

Folding, 5
114

Impermissible working range, 5
70

Unfolding, 5
66
Boom control block, Inspection, 5
48
Boom movements, 5
49

Danger zone, 5
51

Exceptional cases and emergencies,
5
55

Hand signals, 5
54, 5
59

High−voltage lines, 5
52

Prohibited activities, 5
49

Signal with the horn, 5
53

Spontaneous retraction of the boom
cylinders, 5
56

Spontaneous retraction of the support
cylinders, 5
56

Uncontrolled boom movements, 5
57
Boom pedestal, Definition of terms,
2
1
Indexofkeywords
Bouncing boom, 5
74 Components

Electrical components, 2
52

Safety−relevant components, 2
49

Summary, 3
1
C Compressed air cleaning, 2
45, 5
86
Cable control, 3
55 Concrete brake, 3
79
Cable remote control, 5
13 Concrete pump, Definition of terms,

Boom speed, 5
15 2
1

Restarting the pump, 5
16 Control block
Catch basket, 5
88
Boom, 3
75

Support, 3
72
Centralized lubrication system

Grease, 6
13 Control cabinet, 3
21

Low temperature grease, 6
13
Ergonic Graphic Display, 3
23
Check functional fluids, 5
2 Control devices
Chute, 3
89

Agitator direction of rotation emer

gency manual operation, 3
70
Cleaning, 2
43, 5
84
Agitator/water pump emergency ma


Catch basket, 5
88 nual operation., 3
70

Cement bags, 5
90
Boom control block, 3
75

Cleaning agents, 2
44
Cable control, 3
55

Compressed air, 2
45
Control cabinet, 3
21

Compressed air cleaning, 5
86, 5
100
Control panel, 3
50

Drain off the leavings, 5
96, 5
104

Control panel on the outside of the ma

chine, 3
53

Hazards, 2
44
Emergency operation, 3
70

High−pressure water cleaning, 5
90,
Hydraulic fluid radiator, 3
86
5
95
Main hydraulic pump emergency con


Hopper, 5
104 trol lever, 3
70

Leavings, 5
85
Pump control system, 3
70

Methods of cleaning for delivery lines,
Radio control system, 3
58
5
92
Support control block, 3
72

Notes, 5
84
Vibrator, 3
85

Post−cleaning procedure, 2
45
Control panel, 3
50

Post−washing operations, 5
106

Preparations for cleaning, 5
87 Control panel on the outside of the
machine, 3
53

Rotor pump, 5
104

Sponge ball, 5
87 Corner bearing load, 2
27, 5
24

Suction cleaning, 5
93

Truck superstructure, 5
106

Using high−pressure water pump,
D
5
107 Danger zone, 2
4, 2
7

Wash−out adaptor, 5
89
Boom movements, 5
51
Cleaning agents, 2
44
Delivery line systems, 2
8
Clearance
End hose, 2
8, 2
35

From high−voltage lines, 2
20
Hopper, 2
8

Machine, 2
8

To delivery lines, 2
39

Placing boom, 2
7
Clearances

Pumping operations, 5
71

Minimum clearance from pits, 5
20

Set−up site, 5
19

Safe clearance from pits, 5
21

Support legs and support feet, 2
7
Cold weather, 2
36, 5
50
Supports, 5
34
i
 Indexofkeywords
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
1

Hoseman, 2
2

Machine, 2
2

Machine operator, 2
2

Maintenance, 2
3

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
1

Truck mixer driver, 2
3

Working area, 2
4, 2
6
Delivery line

Cleaning, 5
91

Cleaning by reverse pumping, 5
93

Cleaning with compressed air, 5
100

Cleaning with water under high pres

sure, 5
95

Description of the functions, 3
13

Measuring the wall thickness (Machi

nes without transfer tube), 6
75

Replacing, 6
85
Delivery line systems, 2
37

Clearance to delivery lines, 2
39

Continuation delivery lines, 2
39

Danger zone, 2
8

Definition of terms, 2
1

Fastening delivery lines, 2
39

Opening the delivery line , 2
39

Securing delivery lines, 2
37

Shutting−off, diverting, cleaning, 2
40

Suitable delivery line, 2
37

Tightness and blockages, 2
38
Description of the functions

Pump, 3
15

Vacuum system, 3
17
Designated use, 2
9

Inspection intervals, 2
10
Discharge voltage pattern, 2
20
ii
Driving, 2
30, 4
1

Before moving off, 4
2

During the journey, 4
3

Hand signals, 4
1, 4
4
Driving position

Folding the boom, 5
114

Retracting the supports, 5
115
Dry running cut–out, High–pressure
water pump, 3
38, 3
48
E
Boom filter, 5
45
Ear defenders, 2
17
EGD, see Ergonic Graphic Display,
3
23
Electrical components, 2
52
Electrical power, 2
51

Power at the construction site, 2
52
Electromagnetic compatibility, 3
7
Electrostatic charging, 2
23
EMC, 3
7
EMERGENCY SHUT–DOWN button,
3
61, 3
65, 5
47
EMERGENCY SHUT–DOWN function,
5
46
Emissions, Noise, 2
54
End hose, 2
35, 3
78, 5
71

Concrete brake, 3
79

Danger zone, 2
8, 2
35, 5
71

Extending, 2
12

Impermissible end hose, 2
12

Retaining rope, 3
80

With flow restrictor, 3
79
EOC, Ergonic Output Control, 3
45
Ergonic Graphic Display, 3
23

HOME, 3
29

Info, 3
44

Maintenance, 3
42

Menu structure, 3
28

Operating elements, 3
23

Pump settings, 3
39

Pump status, 3
32

Service, 3
43

Start screen, 3
29

Symbols, 3
25
Ergonic Output Control, 3
45
Exceptional cases and emergencies,
5
55
Exhaust fumes, 2
54
Extensions, End hose and placing
boom, 2
12
F
Face mask, 2
17
Filter

Suction filter, 5
44

Vacuum meter, 5
44
Filter change

Pressure filter, 6
41

Suction filter, 6
35

Ventilation filter, 6
47
Filter functions

Boom filter, 5
45

Suction filter, 5
44
Flared screwed joint, 6
5
Flash over, 2
22
Flow restrictor on the end hose, 3
79
Fumes, Exhaust, 2
54
Function checks, 6
33

Agitator safety cutout, 5
42

Boom control block inspection, 5
48

EMERGENCY SHUT−DOWN function,
5
46

Filter functions, 5
44

Pump, 5
40

Vacuum gauge, 5
41
Function description, 3
13

Boom, 3
13

Delivery line, 3
13

Hydraulic control, 3
13

Support legs, 3
13
Functional fluids, 2
55, 6
6
H
Hand signals, 4
1, 5
54

Boom movements, 5
59

Driving, 4
4

Pumping operations, 5
59
Hard hat, 2
17
High–pressure delivery, 2
13

High–pressure water cleaning, 5
90
High–pressure water pump

Cleaning the screen, 6
80

Cleaning using, 5
107

Dry running cut−out, 3
38, 3
48

Fill−level sensor in the water tank, 3
49

Maintenance card, 6
79

Switch−on conditions, 3
49

Technical description, 3
82
High–voltage lines, 2
20, 5
52

Clearances, 2
20

Procedure in the event of a flash over,
2
22
Hopper

Cleaning, 5
104

Danger zone, 2
8
Hoseman, Definition of terms, 2
2
Hoses, Maintenance, 6
51
Hydraulic control, Description of the
functions, 3
13
Hydraulic fluid, 6
6

Full fluid change, 6
27

Radiator, 3
86
Hydraulic fluid radiator, 3
86
Hydraulic hoses, 2
53
Hydraulic system, 3
14
Hydraulic systems, 2
53
I
Responsibility of the machine operator,
Icons, 1
3
Immobiliser, 5
1
Impermissible end hose, 2
12
Impermissible working area, 2
6,
2
12
Impermissible working range, 5
70
Inspection intervals, 2
10
Interlock, 5
33, 5
115
L 6
35
Leavings, 5
85
Liability, Exclusion, 2
13
Lifting loads, 2
11, 2
24
Lifting points, 2
32
Indexofkeywords
Loading, 2
24, 2
32, 4
8

Lifting points, 2
32
Lubricant analysis, 6
8
Lubricant recommendation

Agitator gearbox, 6
12

Engine oil, 6
12

General, 6
9

Greases, 6
13

Hydraulic fluids, 6
11

Low temperature grease, 6
13

Oils, 6
12

Pump tube grease, 6
13

Rotor gearbox, 6
12

Slewing gear transmission, 6
12

Transfer gearbox, 6
12

Transmission oil, 6
12
Lubrication

Grease, 6
13

Placing boom TMM 24/TMM 26, 6
81

TR 27 boom pedestal, 6
83
M
Machine

Danger zone, 2
8

Definition of terms, 2
2

Moving machine components, 2
42

Observing, 2
42
Machine operator

Definition of terms, 2
2
2
14
Maintenance, Definition of terms, 2
3
Maintenance cards

Adjusting the hopper on rotor pumps,
6
71

Adjusting the pressure rollers, 6
57

Changing the hydraulic fluid, 6
27

Changing the oil in the vacuum pump,
6
23

Changing the pressure filter element,
6
41

Changing the suction filter element,

Changing the ventilation filter element,
6
47

Function checks, 6
33

High−pressure water pump, 6
79

Hoses, 6
51

Lubricating the pressure rollers, 6
66

Lubricating the TMM24/TMM26 pla

cing boom , 6
81

Lubricating the TR 27 boom pedestal,
6
83

Measuring the wall thickness (Machi

nes without transfer tube), 6
75

Replacing the delivery line, 6
85

Replacing the pump tube, 6
63

Rotor gearbox full fluid change, 6
19

Vacuum meter, 6
55

Visual checks, 6
17

Water pressure test on the rotor pump,
6
61
Maintenance intervals, 6
1
Measuring the wall thickness, Machi-
nes without transfer tube, 6
75
Minimum wall thicknesses, 6
78
Mobile machines, 2
25

Set−up site, 2
25

Supporting ground, 2
26
N
Noise emissions, 2
54
O
Operating and control elements,
Power take–off, 5
6
Operating Instructions, 2
15
Operating procedures, 2
15, 2
16
Operator, Definition of terms, 2
2
Output, Ergonic Output Control, 3
45
Overview of the components, 3
1
P
Personal protective equipment, 2
17
Personnel, 2
14

Qualifications, 2
14

Requirements, 2
14

Responsibility of the machine operator,
2
14
Place of work, 2
4, 2
6

Place of work − hoseman, 2
6

Place of work − machine operator, 2
6

Place of work − truck mixer driver, 2
6

Pumping operations, 2
41
iii
 Indexofkeywords
Placing boom, 2
33, 2
36

Climbing, 2
13

Danger zone, 2
7

Definition of terms, 2
1

Extending, 2
12

Procedure in storms, 2
36

Unfolding, 2
33

Wind speeds, 2
36

Working on the placing boom, 2
49
Power, 2
52
Power at the construction site, 2
52
Power take–offs, NA, 5
5
Pressure rollers

Adjusting, 6
57

Lubricating, 6
66
Pressurized water system, 3
81
Profiled ring joint, 6
5
Protective equipment, 2
17, 2
50

Ear defenders, 2
17

Face mask and respiratory protector,
2
17

Hard hat, 2
17

Protective gloves, 2
17

Protective goggles, 2
17

Safety boots, 2
17

Safety harness, 2
17
Protective gloves, 2
17
Protective goggles, 2
17
Pump, 5
40

Description of the functions, 3
15
Pump control system, 3
70
Pump tube, Replacing, 6
63
Pump tube in rotor pumps, Grease,
6
13
Pumping operations, 2
41, 5
71

Agitator hopper, 5
73

Blockages, 5
79

Breaks in pumping, 5
78

Calm pumping, 5
74

Engine, 5
80

Favourable boom position, 5
75

Hand signals, 5
59

Overheating, 5
80

Pumping, 5
77

Restarting, 5
81

Safety, 2
41

Starting pumping, 5
76

Sucking in air, 5
73
iv
Rotor pump
Q
Adjusting the hopper, 6
71
Qualifications, 2
14
Adjusting the pressure rollers, 6
57

Before starting, 5
3
Qualified personnel, Definition of
terms, 2
3
Cleaning, 5
104

Lubricating the pressure rollers, 6
66

Measuring the wall thickness, 6
75
R
Replacing the pump tube, 6
63

Starting up, 5
8
Radio control system
Water pressure test, 6
61

Receiver, 3
60
Rotor pumps, Pump tube grease,

Transmitter, 3
58
6
13
Radio remote control

Boom speed, 5
11

Proportional, 5
10 S

Restarting the pump, 5
12
Safety boots, 2
17
Rating plate
Safety equipment, 2
50, 3
3

Boom, 3
9

Machine, 3
8 Safety harness, 2
17
Reaches, 3
12 Safety–relevant components, 2
49

Extending, 2
11 Set–up site, 2
24, 2
25, 5
17
Ready for operation
Calculation examples for the support

Checking, 2
18 area, 5
25

Rendering the machine ready, 2
18
Corner bearing load, 5
24

Danger zone, 5
19
Regulations, 2
15, 2
16

High−voltage lines, 2
20
Remote control, 5
9
Minimum clearance from pits, 5
20

Support function, 5
32, 5
39, 5
116
Safe clearance from pits, 5
21
Remote control unit, 2
41
Space requirement, 5
18

Support area, 5
23
Removing obstacles, 2
11

Support block, 5
23
Respiratory protection, 2
17

Supporting ground, 5
21
Responsibility of the machine opera-
Supports, 2
28
tor, 2
14
Table of timber block lengths, 5
26
Restarting the pump Signaller, Definition of terms, 2
2

With cable remote control, 5
16
Sinking of the boom, 5
57

With radio remote control, 5
12
Slewing gear transmission, Transmis-
Restrictions
sion oil, 6
12

Bad weather, 5
50

Boom movements, 5
50 Sound power level, 3
10

Cold weather, 2
36, 5
50 Sound pressure level, 3
10

Storm, 5
50 Space requirement, 5
18

Wind, 5
50
Spirit level, 3
74, 5
35
Retaining rope, 3
80
Starting up, 5
1
Rotor gearbox
Functional fluids, 5
2

Full fluid change, 6
19
Immobiliser, 5
1

Transmission oil, 6
12
Rotor pump, 5
8

Test run, 5
1

With cable remote control, 5
13

With radio remote control, 5
10

Stationary machines, 2
24

Lifting machines, 2
24

Loading, 2
24

Set−up site, 2
24

Transporting, 2
24
Storm, 2
36
Subject expert, Definition of terms,
2
3
Support area, 5
23

Calculation example , 5
25

Table of timber block lengths, 5
26
Support block, 5
23
Support legs, Description of the func-
tions, 3
13
Support legs and support feet, Dan-
ger zone, 2
7
Supporting ground, 2
26, 5
21

Corner bearing loads, 2
27
Supports, 2
28, 5
30

Danger zone, 5
34

Forward support feet, 5
37

Forward support legs, 5
36

Interlock, 5
33

Rear support feet, 5
38

Remote control, 5
32, 5
39, 5
116

Spirit level, 3
74, 5
35

Working range, 5
31
Symbols, 1
3

EGD, 3
25
Symbols for the control system, G
1
T V
Technical data, 3
7

Sound power level, 3
10

Sound pressure level, 3
10
Technical description, High–pressure
water pump, 3
82
Technical terms, G
15
Temperatures, Restrictions, 2
36
Test run, 5
1
Tightening torques

Flared screwed joint, 6
5

General, 6
3
Timber blocks, 5
26
TMM 24/TMM 26, Lubrication, 6
81
Towing, 2
31, 4
6
Indexofkeywords
TR 27, Lubrication, 6
83
Transfer gearbox, Transmission oil,
W
6
12 Wash–out adaptor, 5
89
Transmission oil Water, 2
45

Agitator gearbox, 6
12 Water pressure test, Rotor pump,

Rotor gearbox, 6
12 6
61

Slewing gear transmission, 6
12
Water system, 3
81

Transfer gearbox, 6
12
Welding, 2
48
Transporting, 2
24
Wind speeds, 2
36
Transporting goods, 2
11
Working area, 2
4, 2
6
Truck mixer, 2
42

Impermissible working area, 2
5, 2
6,

Definition of terms, 2
1 2
12
Truck mixer driver, 2
42
Impermissible working area, boom,

Definition of terms, 2
3 5
70
Truck superstructure, Cleaning, 5
106
Permitted working area, 2
5
Working range, 5
31

Overlaps, 5
53
U Working with the machine
Uncontrolled boom movements, 5
57
Before starting work, 2
18

Checking that the machine is ready for
Use contrary to designated use, 2
11
operation, 2
18

Climbing the placing boom, 2
13

Rendering the machine ready for ope


Exclusion of liability, 2
13
ration, 2
18

Extending the reach, 2
11

Extensions, 2
12

High−pressure delivery, 2
13

Impermissible end hose, 2
12

Impermissible working area, 2
12

Lifting loads, 2
11

Removing obstacles, 2
11

Transporting goods, 2
11
Vacuum gauge, 5
41
Vacuum meter, 5
44

Venting, 6
55
Vacuum pump

Changing the oil in the vacuum pump,
6
25

Checking the oil level, 6
24
Vacuum system

Description of the functions, 3
17

Vacuum pump, 3
18, 6
23

Ventilation cock, 3
19
Ventilation cock, 3
19
Vibrator, 3
85
Visual checks, 6
17
v
 8 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_0501EN 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 SHUT−DOWN activated

10004 Cooling water excess temperature 12007 Acknowledge EMERGENCY SHUT−DOWN

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_0501EN
 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_0501EN 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_0501EN
 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_0501EN 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_0501EN
 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_0501EN 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

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 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.

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 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

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 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

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 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.

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 Glossary

G22 BP14_002_0501EN