Operating Instructions

for machine operator and maintenance staff

always keep by the machine

Translation of the original Operating Instructions

Stationary
concrete pump BSA 1409 D4

Machine no. 210110932

19−03−04

The paper on which this document is printed is 100% chlorine free E Putzmeister Concrete Pumps GmbH 1994
Putzmeister Worldwide

Deutsch
Putzmeister Concrete Pumps GmbH +49−7127−599−0 pmw@pmw.de

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

España Putzmeister Ibérica S.A. +34−91−428 81 00 recepcion@putzmeister.es

PME Camino de Hormigueras 173
Pol. Ind. Vallecas +34−91−428 81 43 www.putzmeister.es
E− 28031 Madrid
France Putzmeister France +33−164 64 39 39 Infopmf@putzmeister.fr
PMF 3, rue Paul Henri Spaak
ZAE Jean Monnet +33−164 64 39 29 www.putzmeister.fr
77240 Vert Saint Denis
Great Putzmeister Limited +44−1246−2642 00 info@putzmeister.co.uk
Britain Carrwood Road
PMUK GB−Chesterfield +44−1246−26 00 77 www.putzmeister.co.uk
Derbyshire S41 9QB
Türkiye Putzmeister Makine Sanayi ve Tic. A.ƞ +90−282−735−1000 pm@putzmeister.com.tr
PTR G.O.PaƟa Mah.
Naműk Kemal Bulvarű No: 6 +90−282−738−1001 www.putzmeister.com.tr
59500 Çerkezköy / TEKŰRDA

USA Putzmeister America +1−262−886−3200 pmr@putzam.com
PMA 1733 90th Street
Sturtevant, WI 53177 USA +1−262−886−3212 www.putzmeister.com

South Putzmeister S.A. (Pty) Ltd. +27−11−794−37 90 pmsa@icon.co.za

Africa Cnr. Bramm & Citrus St. Honeydew
PMSA P.O.Box 5146 ZA 2118 Cresta +27−11−794−41 19 www.putzmeister.co.za
South Africa
India Putzmeister Concrete Machines Pvt Ltd +918326696000 info@pmw.co.in
PCM Plot No. N4, Phase IV
Verna Industrial Estate, Verna Salcete +91832−6696300 www.pmw.co.in
Goa−403722

Japan Putzmeister Japan Co. Ltd. +81−476−36−8907 info@putzmeister.jp

PMJ
7−4 Misawa, Tomisato−shi +81−476−36−8908 www.putzmeister.jp
Chiba 286−0225, Japan
Korea Putzmeister Korea Co. Ltd. +82−31−433−4541 putzmstr@chollian.net
PMK 59 Huimanggongwon−ro, Chungwang−Dong
Shihwa Ind. complex 2 MA 707−1 HO +82−31−498−7230 www.putzmeister.co.Kr
Shihung−city, Kyonggi−Do, Korea
Russ
OOO Putzmeister−Rus +7−495−775−22−37 info@putzmeister.ru
land Urgumskaja Straße 4, Geb. 31
PMR 129343 Moskau, Russia +7−495−775−22−34 www.putzmeister.ru
 de Übersetzung der Originalbetriebsanleitung
bg Ïðåâîä íà îðèãèíàëíî Ðúêîâîäñòâî çà ðàáîòà
cs Pƙeklad originálního návodu k obsluze
da Oversættelse af den originale driftsvejledning
el MetÜfrash tou prwtotýpou twn odhgiþn leitourgßaj
en Translation of the original Operating Instructions
es Traducción de las instrucciones de servicio originales
et Algupärase kasutusjuhendi tõlge
fi Alkuperäisen käyttöohjeen käännös
fr Traduction des instructions de service originales
hr Prijevod izvornika naputka za uporabu
hu Eredeti üzemeltetési útmutató fordítása
it Traduzione delle istruzioni d’uso originali
lt Eksploatavimo instrukcijos originalo vertimas
lv Lietoơanas pamcbas tulkojums no oriinlvalodas
nl Vertaling van de oorspronkelijke gebruiksaanwijzing
no Oversettelse av original brukerhåndbok
pl TƂumaczenie oryginalnej instrukcji eksploatacji
pt Tradução das Instruções de funcionamento originais
ro Traducerea instrucƣiunilor de funcƣionare originale
ru Gthtdjl abhvtzzjuj herjdjlcndf gj ärcgkefnfwbb
sk Preklad originálneho návodu na obsluhu
sl Prevod izvirnih navodil za uporabo
sv Översättning av original instruktionsbok
tr Orijinal kullanűm kűlavuzunun tercümesi

BP00_030_0911EN
BP00_030_0911EN
 Tableofcontents

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

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

2 Safety regulations
2.1 Definition of terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 1
2.1.1 Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  1
2.1.2 Concrete pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  1
2.1.3 Arm assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  1
2.1.4 Placing boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  1
2.1.5 Base structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  1
2.1.6 Truck mixer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  2
2.1.7 Delivery line systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  2
2.1.8 End hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  2
2.1.9 Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  2
2.1.10 Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  2
2.1.11 Machine operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  2
2.1.12 Hoseman . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  2
2.1.13 Signaller and other auxiliary personnel . . . . . . . . . . . . . . . . . . 2  2
2.1.14 Truck mixer driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Retesting (safety inspection) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  10
2.2.2 Inspection intervals for retesting . . . . . . . . . . . . . . . . . . . . . . . 2  11

2.3 Improper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 12

2.3.1 Transporting goods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  12
2.3.2 Lifting loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  12
2.3.3 Removing obstacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  12
2.3.4 Extending the reach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  12
2.3.5 Extending the placing boom and end hose . . . . . . . . . . . . . . 2  13

210110932 I
 Tableofcontents

2.3.6 Impermissible end hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  13

2.3.7 Impermissible working area . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  14
2.3.8 Climbing the placing boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  14
2.3.9 High
pressure delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  15
2.3.10 Accessories and attachments . . . . . . . . . . . . . . . . . . . . . . . . . 2  15
2.3.11 Changes to the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  15

2.4 Exclusion of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 15

2.5 Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 15
2.5.1 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  16
2.5.2 Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  16
2.5.3 Responsibility of the machine operator . . . . . . . . . . . . . . . . . . 2  16

2.6 Operating Instructions, operating procedures and

other regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 17
2.6.1 Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  17
2.6.2 Operating procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  18
2.6.3 Other regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  18

2.7 Personal protective equipment . . . . . . . . . . . . . . . . . . . . . . . 2 — 19

2.8 Before working with the machine . . . . . . . . . . . . . . . . . . . . . 2 — 21

2.8.1 Checking that the machine is ready for operation . . . . . . . . 2  21
2.8.2 Rendering the machine ready for operation . . . . . . . . . . . . . 2  21

2.9 Danger due to high voltage . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 22

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

2.10 Stationary machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 26

2.10.1 Set
up site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  26
2.10.2 Stationary placing booms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  26
2.10.3 Lifting machines and components . . . . . . . . . . . . . . . . . . . . . . 2  27
2.10.4 Loading and transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  27

2.11 Mobile machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 28

2.11.1 Set
up site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  28

II 210110932
 Tableofcontents

2.11.2 Supporting ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  29

2.11.3 Corner bearing loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  30
2.11.4 Supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  31
2.11.5 Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  33
2.11.6 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  34
2.11.7 Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  35

2.12 Placing booms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 36

2.12.1 Unfolding the placing boom . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  36
2.12.2 End hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  38
2.12.3 Guiding the end hose ergonomically . . . . . . . . . . . . . . . . . . . 2  39
2.12.4 Connecting drills . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  39
2.12.5 Procedure in storms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  40
2.12.6 Concreting in cold weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  40

2.13 Delivery line systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 41

2.13.1 Suitable delivery lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  41
2.13.2 Securing delivery lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  41
2.13.3 Leak tightness and blockages . . . . . . . . . . . . . . . . . . . . . . . . . 2  42
2.13.4 Opening delivery lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  43
2.13.5 Clearance to delivery lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  43
2.13.6 Fastening delivery lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  43
2.13.7 Continuation delivery lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  44
2.13.8 Devices for shutting off, diverting or cleaning delivery lines 2  44

2.14 Pumping operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 45

2.14.1 Place of work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  45
2.14.2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  45
2.14.3 Remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  45
2.14.4 Moving machine components and hot surfaces . . . . . . . . . . 2  46
2.14.5 Constant observation of the machine . . . . . . . . . . . . . . . . . . . 2  47
2.14.6 Truck mixer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  47

2.15 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 48
2.15.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  48
2.15.2 Cleaning agents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  49
2.15.3 Cleaning with compressed air . . . . . . . . . . . . . . . . . . . . . . . . . 2  50
2.15.4 Protection against water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  51
2.15.5 Post−cleaning procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  51

210110932 III
 Tableofcontents

3 General technical description

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

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

3.3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 5

3.3.1 Electromagnetic compatibility (EMC) . . . . . . . . . . . . . . . . . . . 3  6
3.3.2 Machine rating plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  7
3.3.3 Sound pressure level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  8
3.3.4 Sound power level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  8

3.4 Description of the functions . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 10

3.4.1 Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  10
3.4.2 Static base structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  11
3.4.3 Support legs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  11
3.4.4 Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  12
3.4.5 Transfer tube damping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  14
3.4.6 Agitator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  15

3.5 General conditions for using a concrete pump . . . . . . . . 3 — 16

3.5.1 Service life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  16
3.5.2 Site of use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  17
3.5.3 Height of job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  17
3.5.4 Operating temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  18
3.5.5 Centralized lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . 3  19
3.5.6 Dry running cut
out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  21

3.6 Electrical control devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 22

3.6.1 Central module control cabinet . . . . . . . . . . . . . . . . . . . . . . . . 3  23
3.6.2 Ergonic Graphic Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  29
3.6.3 Ergonic Output Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  73
3.6.4 Cable remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  87
3.6.5 Operating panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  89
3.6.6 EMERGENCY STOP button . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  91
3.6.7 Agitator safety cutout (RSA) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  93
3.6.8 Magnetic switches distributor casing . . . . . . . . . . . . . . . . . . . 3  95
3.6.9 Magnetic switch connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  97

IV 210110932
 Tableofcontents

3.7 Hydraulic control devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 99

3.7.1 Water pump lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 100
3.7.2 Pump control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 101
3.7.3 Agitator emergency operation . . . . . . . . . . . . . . . . . . . . . . . . . 3 102
3.7.4 Pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 103
3.7.5 Filter condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 103
3.7.6 Automatic−Piston−Pull (APP) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 104

3.8 Other components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 —105

3.8.1 Hydraulic fluid radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 106
3.8.2 Flushing water pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 107
3.8.3 Vibrator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 109
3.8.4 Exhaust after treatment system . . . . . . . . . . . . . . . . . . . . . . . . 3 110

4 Starting up
4.1 Visual checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 — 1
4.1.1 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  1
4.1.2 Functional fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  2
4.1.3 Condensate water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  3
4.1.4 Lubrication points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  3
4.1.5 Hydraulic fluid radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  3
4.1.6 Water box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  4
4.1.7 Parts in contact withconcrete . . . . . . . . . . . . . . . . . . . . . . . . . 4  5

4.2 Test run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 — 6

4.2.1 Switching on the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  7

4.3 Function checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 — 10

4.3.1 Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  10
4.3.2 EMERGENCY STOP buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  12
4.3.3 Function check of the agitator safety cutout (RSA) . . . . . . . 4  13
4.3.4 Acknowledging the agitator safety cutout . . . . . . . . . . . . . . . 4  15
4.3.5 Filter condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  17
4.3.6 Agitator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  19
4.3.7 Gate valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  20
4.3.8 Flushing water pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  21
4.3.9 Vibrator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  23
4.3.10 Switching off the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  24

210110932 V
 Tableofcontents

5 Transport, setting up and connection

5.1 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 — 1
5.1.1 Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  1
5.1.2 Lifting eyes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  2
5.1.3 Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  4
5.1.4 F8 chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  4
5.1.5 F25 chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  4
5.1.6 F80 chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  5
5.1.7 Crawler track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  7
5.1.8 Static base structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  7

5.2 Hand signals for driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 — 8

5.3 Requirements for the set–up site . . . . . . . . . . . . . . . . . . . . . 5 — 10

5.4 Setting up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 — 14

5.5 Stationary delivery line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 — 18

5.5.1 Danger zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  19
5.5.2 Instructions for laying the line . . . . . . . . . . . . . . . . . . . . . . . . . . 5  20
5.5.3 Fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  22
5.5.4 SK delivery line system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  26

5.6 Rod side – piston side feed . . . . . . . . . . . . . . . . . . . . . . . . . . 5 — 27

5.7 Flushing water pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 — 29

VI 210110932
 Tableofcontents

6 Pumping operations
6.1 Preconditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 1
6.1.1 Remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  2

6.2 Hand signals for pumping . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 3

6.3 Filling the machine with fuel . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 5

6.4 Filling the DEF container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 6

6.5 Considering concrete properties . . . . . . . . . . . . . . . . . . . . . 6 — 10

6.6 Filling the agitator hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 11

6.7 Inserting the stop plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 12

6.8 Starting pumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 13

6.9 Pumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 14
6.9.1 Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  15
6.9.2 Transfer tube damping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  17
6.9.3 Blockages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  18
6.9.4 Breaks in pumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  19
6.9.5 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  20
6.9.6 Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  20
6.9.7 Exhaust after treatment system . . . . . . . . . . . . . . . . . . . . . . . . 6  22
6.9.8 Restarting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  26

6.10 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 27
6.10.1 Preparations forcleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  30
6.10.2 Delivery line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  36
6.10.3 Hopper, delivery cylinder and Stransfer tube . . . . . . . . . . . . 6  43
6.10.4 Post
cleaning procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  49

6.11 Measures for preserving the value of stationary

concrete pumps placed in storage . . . . . . . . . . . . . . . . . . . . 6 — 51

210110932 VII
 Tableofcontents

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

Index of key words

VIII 210110932
 GuidetotheOperatingInstructions

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 Concrete Pumps GmbH

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_0802EN 1IX
 GuidetotheOperatingInstructions

1X BP01_001_0802EN
 GuidetotheOperatingInstructions

1.1 Foreword The aim of these Operating Instructions is 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 economically. Observing
these instructions helps to avoid danger, to reduce repair costs and
downtimes, and to increase the reliability and service life of the
machine.

The Operating Instructions must be supplemented by the relevant

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

person charged with carrying out work with and on the machine eg
− in operation, including setting up, fault rectification in the course of
work, removal of production waste, maintenance and disposal of
fuels and consumables;
− in service (maintenance, inspection, repair); and/or
− transport.

The generally−recognized rules of technology for safe and proper

working must be observed in addition to the Operating Instructions
and mandatory rules and regulations for accident prevention and
environmental protection in the country and place of use of the
machine.

AP01_002_0802EN 11
 GuidetotheOperatingInstructions

The Branch or Agent serving you, or the Aichtal Works, will be happy
to give you more information should you have any questions follow

ing your study of the Operating Instructions.

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 do not describe the engine; the en

closed operating instructions issued by the engine manufacturer
apply for this.

Modifications are made from time to time in the interests of constant

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

The copy of the Operating Instructions intended for the machine will
be replaced in full in the event of any amendment.

The reproduction, distribution and utilization of this document as well

as the communication of its contents to others without explicit author

ization is prohibited. Offenders will be held liable for the payment of
damages. All rights reserved in the event of the grant of a patent,
utility model or design.

© Putzmeister Concrete Pumps GmbH 1994

12 AP01_002_0802EN
 GuidetotheOperatingInstructions

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

" Task symbol

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

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

See also the maintenance cards:

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

The following special tools are required:

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

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

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

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

BP01_003_0601EN 13
 GuidetotheOperatingInstructions

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

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

of the danger precisely.

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

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

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

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

14 BP01_003_0601EN
 GuidetotheOperatingInstructions

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

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

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

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

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

BP01_003_0601EN 15
 GuidetotheOperatingInstructions

16 AusgleichsseiteEN
 Safetyregulations

2 Safety regulations

These safety regulations conform to the chapters Terms, definitions,

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

Safety manual Concrete delivery and placing machines".

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

tions. This chapter is particularly suitable as an initial basic instruc

tion for new employees.

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

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

information:
 EN 12001, Conveying, spraying and placing machines for con
crete and mortar
 EN 12100, Safety of machinery,
 EN 60204−1, Electrical equipment of machines.
 In the Federal Republic of Germany: DGUVRegulation101−012,
Concrete pumps and placing booms.

BP03_081_1701EN 2I
 Safetyregulations

2II BP03_081_1701EN
 Safetyregulations

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

2.1.1 Machine For the purposes of this Safety Manual, concrete delivery and plac

ing machines are defined as:
− Truck−mounted concrete pumps (an ensemble of truck and con

crete pump with and without placing boom). The safety regula

tions issued by the truck manufacturer also apply to the truck.
− Truck mixer concrete pump (an ensemble of truck mixer, con

crete pump and placing boom). The safety regulations issued by
the truck mixer manufacturer and by the truck manufacturer also
apply to truck mixer concrete pumps.
− Stationary concrete pumps
− Stationary placing systems (an ensemble of placing boom and
base structure)

2.1.2 Concrete pump For the purposes of this Safety Manual, concrete pumps are de

fined as devices which are designed to deliver concrete to place

ment sites via pipes or hoses.

2.1.3 Arm assembly Arm assembly is a synonym for placing boom and can be used in

terchangeably.

2.1.4 Placing boom For the purposes of this Safety Manual, placing booms are defined
as powered, slewable devices consisting of one or more swinging
or folding sections for guiding the delivery line.

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

BP03_082_1901EN 21
 Safetyregulations

2.1.6 Truck mixer For the purposes of this Safety Manual, truck mixers are defined as
vehicles with mixing equipment for transporting concrete.

2.1.7 Delivery line systems For the purposes of this Safety Manual, delivery line systems are
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.

2.1.8 End hose For the purposes of this Safety Manual, end hose is defined as the
hose that is fitted on the placing boom at the end of the delivery line
for distributing the concrete. There must be no couplings, spouts,
discharge stops or other items fixed to the outlet end of the end
hose unless they are approved by the manufacturer.

2.1.9 Manufacturer Any natural or legal person that markets a machine or incomplete
machine that is dealt with in this Safety Manual.

2.1.10 Operator Authorized representative of the owner of the concrete pumps

and/or placing booms. The operator is responsible for the use of
these machines.

2.1.11 Machine operator Persons trained in and charged with the operation of concrete
pumps and placing booms.

2.1.12 Hoseman Persons instructed by the site management in how an end hose is
guided. Hosemen must be able to independently evaluate all dan

gerous situations which may occur in the area of the end hose and
react according to the situation.

2.1.13 Signaller and other Persons instructed by the site management to help the machine op

auxiliary personnel erator in his work if the latter is unable to observe all areas of oper

ation and danger zones. Signallers must be able to independently
evaluate all dangerous situations which may occur when working
with a concrete pump and/or placing boom and react according to
the situation. The signaller must have a suitable means of communi

cation with the machine operator.

22 BP03_082_1901EN
 Safetyregulations

2.1.14 Truck mixer driver Persons who supply the concrete pump with concrete from a truck
mixer. Truck mixer drivers must be instructed by the machine oper

ator to operate the operating elements on the concrete pump pro

vided for their use. Truck mixer drivers must be able to indepen

dently evaluate all dangerous situations which may occur when
working in the area of the hopper of a concrete pump and react ac

cording to the situation.

2.1.15 Subject expert For the purposes of this Safety Manual, a subject expert is defined
as a person who, through their professional training, their pro

fessional experience and their recent professional activity, has the
required specialist knowledge to inspect the tools.

2.1.16 Qualified personnel Persons who have completed specialist training for a particular ac

tivity which qualifies them to carry out their roles.

2.1.17 After Sales Service Qualified personnel employed by the manufacturer who are respon

personnel sible in particular for maintenance of the machine.

2.1.18 Maintenance Maintenance includes all measures required to inspect, maintain

and repair a machine.

BP03_082_1901EN 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_082_1901EN
 Safetyregulations

Pos. 0 Designation Explanation

1 Machine operator In normal operation, with the remote control
2 Place off work
Pl k Hoseman At the end hose in the danger zone
(during pump

pump
3 Signaller In the machine operator’s range of vision
ing oper

oper
4 Auxiliary personnel As machine operators of the manual placing system
ations)
5 Truck mixer driver At the hopper in the danger zone
Area with a radius of the reach of the placing boom
6 Permitted
+ end hose length
Working area
The end hose must not be moved backwards be

7 Impermissible
yond the vertical of the placing boom
Risk of injury when pumping is started, during
pumping operations, when removing a blockage
8 At the end hose
and during cleaning 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 Risk of crushing when setting up or dismantling the
10 Danger zone
or area of the base machine
structure
Any presence on or below the machine when the
11 On the machine
pump is in operation is prohibited
Risk of injury during cleaning procedures and when
12 At the hopper
the hopper is being filled using a truck mixer
Area of the delivery Hazard posed if lines burst, risk of injury from crush

13
line systems ing or shearing, particularly with gate valves
14 Structure or area being concreted Example

BP03_082_1901EN 25
 Safetyregulations

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

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

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

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

ual contact.

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

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

The working area must be secured and clearly identified. Suitable

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

Impermissible working Because of their high manoeuvrability, some placing booms can
area also be shifted into positions for which they are not designed. This
may overload or damage the placing boom. Placing booms must
therefore only be moved within the permitted working area (see also
page214).

26 BP03_082_1901EN
 Safetyregulations

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

The danger zone varies within the working area and depends on
the activity being carried out and the position of the placing boom,
if one is present. Danger zones must be secured and clearly identi

fied. The machine operator must be capable of seeing the danger
zone at all times and under all circumstances. If necessary, he must
appoint a signaller to supervise the danger zone.

Depending on the working situation, places of work may oc

casionally fall within the danger zone, especially the place of work
of the hoseman and the truck mixer driver. If a place of work falls
within the danger zone, increased caution is required and suitable
personal protective equipment is prescribed. Persons who are auth

orized to be present in such a place of work must use their own
discretion to assess dangerous situations and be able to react ac

cording to the situation.

The machine operator is responsible for safety in the danger zone

of the machine whilst the machine is in use.

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

Support legs and sup There is a risk of crushing in the swing
out and extension zone for
port feet 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.

BP03_082_1901EN 27
 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 oper

ations, when removing a blockage and during cleaning procedures
is the area around the end hose in which the end hose may swing
out. The diameter of the danger zone is twice the end hose length.

Hopper In the area of the hopper, there is a risk of becoming trapped be

tween the truck mixer and the hopper and of being sprayed with
concrete. There is a risk of being crushed and of injury by shearing
from the transfer tube. There is a risk of becoming caught in the ro

tating agitator.

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

grated in delivery line systems.

28 BP03_082_1901EN
 Safetyregulations

2.2 Designated use The machine must only be operated as intended and in technically
perfect condition. All protective and safety
oriented devices, par

ticularly removable protective devices and EMERGENCY STOP de

vices, must be available and fully functional.

The machine is designed exclusively for the delivery and placing of

concrete up to a bulk density of 2400 kg/m3. It must only be used
for pumping operations on construction sites. The maximum con

crete pressure must not exceed that specified on the rating plate or
in the check book.

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

BP03_082_1901EN 29
 Safetyregulations

2.2.1 Retesting (safety in- After initial commissioning of the machine, the operational safety of
spection) the machine must be checked regularly by a subject expert. The
inspection intervals depend on the age of the machine. The older
the machine, the greater the probability of damage. For this reason,
regular retesting of the machine, appropriate to its age, must be
carried out in order to detect damage in good time. Retesting
should be carried out in accordance with the inspection intervals
listed below.

Retesting must consist of the following:

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

Retesting must include components which are used in conjunction

with the machine (in particular, delivery line components and acces

sories).

Furthermore, information provided by the manufacturer to the oper

ator with reference to special instructions for maintenance and in

spection must be observed.

210 BP03_082_1901EN
 Safetyregulations

2.2.2 Inspection intervals The inspection intervals are fixed as follows:

for retesting
Machines up to and including 5years old:
Inspect after every 1000operating hours or 1year, whichever is
soonest. The interval is repeated after every retest.

Machines more than 5years old:

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

Machines more than 10years old:

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

The day of initial commissioning in accordance with the handover

report and the machine’s operating hours meter are definitive for
the intervals. This operating hours meter records the hours of
pumping operations. The operating hours meter must always be
kept in good working order. It must not be tampered with. For ma

chines without an operating hours meter, the operating hours must
be recorded in a traceable form in writing.

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

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

Notwithstanding national legislation, the operator can be liable in

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

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

BP03_082_1901EN 211
 Safetyregulations

2.3 Improper use Any use of the machine which is not described in section2.2,en

titled Designateduse", or which extends beyond the uses de

scribed in this section is deemed to be contrary to designated use.
The manufacturer accepts no liability for damage resulting from
such use. Some examples of conceivable improper uses are given
below.

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

ceeded.

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

wz0006

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 placing boom and the lift

ing equipment for the extension have differing pivot points and
modes of control, it is not possible to co−ordinate their movements.

212 BP03_082_1901EN
 Safetyregulations

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

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

If a longer end hose is used, the diameter of the danger zone is

also increased (see also page238).

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

wz0016

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

wz0195

BP03_082_1901EN 213
 Safetyregulations

2.3.7 Impermissible work- During pumping operations, the end hose must not be moved
ing area backwards beyond the vertical axis of rotation of the placing boom.

wz0026

In addition to this, additional impermissible working areas exist, de

pending on the machine model and manufacturer, which are de

scribed in the Operating Instructions.

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 climbing aid.

wz0037

214 BP03_082_1901EN
 Safetyregulations

2.3.9 High-pressure deliv- It is prohibited to deliver concrete at high pressure (delivery pres

ery sure greater than 85bar) through the delivery line of the placing
boom. Delivery line elements are marked with the maximum per

missible delivery pressure. The delivery line and end hose are only
suitable for delivery pressures of up to 85bar until the wear thresh

old is reached. For the wear threshold, refer to the Operating In

structions for the machine.

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

2.3.11 Changes to the ma- You are not allowed to carry out your own changes to the machine.
chine Changes must always be approved by the manufacturer.

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

Unless the responsibility of the manufacturer, the warranty will be

invalidated in the following situations in particular:
− use contrary to designated use
− incorrect operation, maintenance and repair
− use of spare parts or accessories other than original manufac

turer’s spare parts and accessories or their equivalents
− conversions, alterations or modifications to the machine
− fitting of accessories and attachments not approved by the
manufacturer
− adjustment of safety pressures, speeds of movement, power out

puts, speeds of rotation and other settings to values other than
those set in the works

2.5 Personnel The operator must ensure that only persons who are qualified or
have received the necessary instruction work on or with the ma

chine. It is the responsibility of the operator to carry out regular (e.g.
annual) safety briefings for their employees. Suitable training can
be requested from the machine manufacturer. The operator must
clearly define who is responsible for operation and maintenance of
the machine. The operating company must also ensure that only
persons commissioned to work on the machine do so. In addition,
the operator should provide the necessary personal protective
equipment.

BP03_082_1901EN 215
 Safetyregulations

2.5.1 Requirements Persons operating or carrying out maintenance work on the ma

chine must meet the following requirements:
− They must be aged 18 years or over.
− They must be physically and mentally capable.
− They must be physiologically capable (rested and not under the
influence of alcohol, drugs or medication).
− They must have been instructed in the operation and mainten

ance of the machine.
− They must have demonstrated their competence to the operator.
− They can be expected to reliably execute the tasks with which
they are charged.

The operating personnel must not wear loose garments or jewellery,

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

All persons working on or with the machine must concentrate on the

task at hand and not be distracted, particularly by smartphones
and music played through headphones.

2.5.2 Qualifications Persons who are being trained, introduced and instructed in the
use of the machine are only permitted to operate the machine
under the constant supervision of experienced personnel.

If you do not have qualified personnel, suitable workshop equip

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

2.5.3 Responsibility of the The operator must define the responsibility of the machine operator
machine operator (including in respect to national road traffic regulations) and em

power the machine operator to reject instructions from third parties
prejudicial to safety. The machine operator must be able to reject
the site of operations in the event of doubts regarding technical
safety.

216 BP03_082_1901EN
 Safetyregulations

2.6 Operating Instructions, operating procedures and other regulations

2.6.1 Operating Instruc- Personnel that are authorised to work on the machine must have
tions read the Operating Instructions, particularly the "Safety Regula

tions" section, and the Safety Manual before working with the ma

chine. 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.

As the operator, you must always make sure that the Operating In

structions are available. The Operating Instructions and check book
must always be kept to hand at the site of use of the machine (in
the tool compartment or container provided for this purpose).

As the operator, you must have personnel working on the machine

confirm in writing their knowledge, understanding and application
of the Operating Instructions and Safety Regulations and Safety
Manual. At regular intervals of at least once a year, check that per

sonnel are conscious of safety and the hazards involved in their
work and are taking account of the Operating Instructions.

Personnel entrusted with work on the machine must observe all

safety instructions and hazard warnings, and must be familiar with
the machine itself. You must practice all the operating procedures
described in the Operating Instructions (extending the supports,
operating the placing boom, shifting the placing boom into the driv

ing position, preparing the vehicle for moving, etc.) under the
supervision of a subject expert until you are certain you can ex

ecute them safely. Ask questions if there is something you have not
understood. Begin operating the machine only once you are fully
and explicitly familiar with the layout and significance of all the con

trol and monitoring devices and the method of operation of the ma

chine.

BP03_082_1901EN 217
 Safetyregulations

2.6.2 Operating procedures The operator must produce operating procedures for their person

nel in accordance with national regulations. These operating pro

cedures must include instructions covering the duties involved in
supervising and notifying special organisational features, e.g. or

ganization of work, working procedures or the personnel entrusted
with the work. Furthermore, reference must be made to other gen

erally 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 familiarize 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.

218 BP03_082_1901EN
 Safetyregulations

2.7 Personal protective In order to reduce risks to personnel, personal protective equip

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

Personal protective equipment must, as a minimum, comply with

the requirements of the specified standards.

Safety helmet
A safety helmet protects your head against, for instance, falling con-
crete or parts of the delivery line in the event of a hose bursting.
(DIN EN 397; Industrial safety helmets)

Safety footwear
Safety footwear protects your feet against falling objects and against
penetration by projecting nails.
(EN ISO 20345; Safety footwear for professional use; category S3)

Hearing protectors
Hearing protectors protect you against the noise generated by the
machine when you are standing close to it.
(DIN EN 352-1; Hearing protectors – General requirements – Part 1:
Earmuffs
or
DIN EN 352-3; Hearing protectors – General requirements – Part 3:
Earmuffs on safety helmet)

BP03_082_1901EN 219
 Safetyregulations

Protective gloves
Protective gloves protect your hands against aggressive or chemical
substances, as well as against mechanical effects (e.g. impact) and
cutting injuries.
(DIN EN 388; Protective gloves against mechanical risks;
Class 1111)

Protective goggles
Protective goggles protect your eyes against injuries from concrete
spatters or other particles.
(DIN EN 166; Personal eye-protection – Specifications)

Safety harness
When working at height, use the climbing aids and working plat-
forms provided for reasons of safety or wear a safety harness. The
relevant national regulations must be complied with.
(DIN EN 361; Personal Protective Equipment Against Falls from a
Height – Full Body Harnesses; Category III)

Face mask and respiratory protection

A face mask and respiratory protection protect you against particles
of building materials which could enter your body through your respi-
ratory passages (e.g. concrete admixtures).
(DIN EN 149; Respiratory protective devices – Filtering half masks
to protect against particles – Requirements, testing, marking;
Class FFP1)

220 BP03_082_1901EN
 Safetyregulations

2.8 Before working with the machine

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

2.8.2 Rendering the ma- As machine operator, you are responsible for rendering the ma

chine ready for oper- chine ready for operation. This also includes topping up the func

ation tional 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 be

fore you change the mode of control (control block, control console
or remote control).

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

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

BP03_082_1901EN 221
 Safetyregulations

2.9 Danger due to high voltage

2.9.1 High–voltage lines Whenever you touch a high−voltage line, there is a risk of death for
all persons either on the machine or in its vicinity or who are con

nected to it (via the remote control, end hose, etc.). A spark can
jump across from a high
voltage line even if you just approach it
and this will energize the machine and the surrounding area.

2.9.2 Discharge voltage In the event of a flash over, what is known as a discharge voltage
pattern pattern" is formed in the vicinity of the machine. The voltage de

creases from the inside to the outside in this discharge voltage pat

tern. If you step inside this discharge voltage pattern, you will
bridge different potentials. This will cause a voltage corresponding
to the potential difference to flow through your body.

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

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

Rated voltage [V] Minimum clearance [m]

up to 1kV 1.0

1kV to 110kV 3.0

110kV to 220kV 4.0

220kV to 380kV 5.0

unknown rated voltage 5.0

The specified clearances are minimum requirements. You must ob

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

222 BP03_082_1901EN
 Safetyregulations

wz0116

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

age lines and the placing boom swaying in the wind must also be
taken into consideration. You should further note that where air hu

midity is high, clearances greater than the minimum clearances
shown above are always necessary.

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

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

The same minimum clearances are necessary when driving under

overhead cables.

In the event that this minimum clearance cannot be maintained

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

Should you have any doubts, it is better to forgo the use of the plac

ing boom and to lay a separate delivery line, for instance.

BP03_082_1901EN 223
 Safetyregulations

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

2.9.5 Procedure in the If, despite all precautions, a flash over occurs, stay calm and do not
event of a flash over move (potential differential) or touch anything.

wz0126

If your machine comes into contact with high−voltage lines:

− Warn people standing outside the area not to approach or touch
the machine.
− Have the power switched off.
− Only leave the machine once you are sure that the line you have
touched or damaged has been de
energized.

224 BP03_082_1901EN
 Safetyregulations

Electricity generator works are always equipped with automatic

start
up systems. If a circuit breaker trips, the short−circuited line
will be switched back on again after a brief interval. Brief intervals
where the voltage is absent create a false sense of safety.

You must not move or rescue injured persons until a representative

of the power station has notified you that the line has been switched
off.

A radio remote control system only protects the machine operator if

he is standing outside the discharge voltage pattern.

2.9.6 Earthing in the event Working in the vicinity of transmitters (radio transmitter, etc.) can
of electrostatic charg- result in faults in the radio remote control system and dangerous
ing electrical charges in the machine. Persons who bridge the charged
parts to the earth are heavily charged on contact.

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

earthing may be carried out by trained personnel.

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

voltage lines (see also page222) must be maintained and the
instructions regarding storms and bad weather (see also
page240) must be observed.

If you have any further questions about earthing the machine,

please contact site management or the operator of the machine.

2.9.7 Earthing on construc- When carrying out work in the area of special installations (particu

tion sites with special larly overhead lines for railways or substations), it may be the case
equipment that the machine needs to be earthed upon request and in con

sultation with the operator of the special installation. This earthing
must only be carried out by qualified personnel.

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

voltage lines (see also page222) must be maintained and the
instructions regarding storms and bad weather (see also
page240) must be observed.

BP03_082_1901EN 225
 Safetyregulations

2.10 Stationary machines

2.10.1 Set-up site Stationary machines are generally used on a construction site for a
lengthy period. For this reason, site management should prepare
the set
up site carefully. Site management must deliver the necess

ary documents in good time in order to be able to prepare the
foundations, base plates or similar on time.

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

resses.

Please also observe section2.11.1, Mobile machines, Set−up site.

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

226 BP03_082_1901EN
 Safetyregulations

2.10.3 Lifting machines and Machines which are transported to the set
up site in individual parts
components or not under their own power must only be lifted with suitable lifting
equipment in accordance with the specifications in the Operating
Instructions. The lifting gear on the machine must be capable of ac

cepting the lifting gear and lifting the load. No
one should stand
under suspended loads. Before work is started, a subject expert
must check that the assembled machine is working properly.

2.10.4 Loading and trans- Only use suitable means to load and transport stationary machines.
porting Ensure that no
one can be injured by the machine tipping over or
slipping.

If there are transport fixtures provided for the machine or its individ

ual components, only these should be used. The machine/compo

nents must be properly secured during transport. The transport ve

hicle and machine must be marked to conform with the road traffic
regulations in the country concerned if they are to use the public
highway.

Please also observe section2.11.5, Mobile machines, Driving.

BP03_082_1901EN 227
 Safetyregulations

2.11 Mobile machines

2.11.1 Set-up site Site management must prepare and assign the set−up site. It is the
machine operator who takes responsibility for setting up the ma

chine safely. The machine operator must inspect the set
up site pro

posed by site management and must refuse to set the machine up
at the site of operations if there are any doubts regarding safety.

As machine operator, you must familiarise yourself with the working

area and surroundings before work is begun. The working area and
surroundings include, in particular, obstacles in the work and travel

ling areas, the load−bearing capacity of the supporting ground and
any barriers separating the construction site from public roads.

The set
up site must have sufficient lighting to ensure safe oper

ation of the machine. Ensure that the set
up site is adequately lit.

Do not set up the machine in areas where equipment may fall down.

Incidents of overlapping with the working areas of other machines

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

You must also check the approach route to the site where the ma

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

Always ask for a signaller if you need to reverse. If necessary, have

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

228 BP03_082_1901EN
 Safetyregulations

2.11.2 Supporting ground Find out the load−bearing capacity of the supporting ground. The
site management will be able to state the permitted ground pres

sure. If the load−bearing capacity is unknown, assume the that
worst case scenario applies.

wz0087

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

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

The support area must be enlarged as required. Support blocks

and timber 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. Inter

rupt the pumping operation if the machine becomes unstable. Fac

tors which reduce stability include, for instance:
− Modifications to the ground conditions, particularly caused by
rain water or the thawing of frozen ground
− the support sinking on one side
− fluid losses through leaks in the support hydraulics

BP03_082_1901EN 229
 Safetyregulations

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

wz0095

The force transferred to the ground by each support leg diffuses

through the soil in a conical pattern at an angle of 45_. Safe clear

ance to the pits and slopes must be maintained, and such clear

ance must be determined in accordance with the nature of the
ground. The safe clearance is measured from the bottom 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.

230 BP03_082_1901EN
 Safetyregulations

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

Swing out and telescope the support legs to their end positions in
sequence. Intermediate positions are prohibited to guarantee sta

bility. Exceptions are machines which have been equipped by the
manufacturer with a device which allows secure erection with a re

duction in support. Check the corresponding notes in this regard in
the operating instructions.

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

is stopped, the entire volume of fluid is available for the remaining
movements, and can increase their speeds. Depending on the de

sign, it may be the case that carrying out several movements at
once (as opposed to carrying out a single movement at maximum
speed at any one time) does not bring any advantage in terms of
time. Carrying out several movements at once requires an in

creased level of attentiveness.

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.

BP03_082_1901EN 231
 Safetyregulations

The machine must be made level in all directions. Provided the

manufacturer does not state otherwise, the maximum permissible
deviation from the horizontal is 3_. Greater deviations from the hori

zontal overload the slewing gear for the placing boom as well as its
overall support structure, jeopardising the stability of the machine.

wz0106

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.

232 BP03_082_1901EN
 Safetyregulations

2.11.5 Driving When preparing the machine for driving, you must perform the fol

lowing tasks in particular:
− The placing boom must be folded in fully and positioned on the
placing boom support provided.
− The support legs and support feet must be fully retracted and
secured.
− Raised or locked axles must be lowered and released.
− Accessories and moving parts belonging to the machine must be
safely stowed/secured.
− The maximum permissible gross weight must not be exceeded.

While the vehicle is being driven, the delivery line, pump and
hopper must be empty. If there is concrete residue in the hopper,
there is a risk of injury from the concrete residue, which may be
thrown out while the vehicle is in motion. This also affects the centre
of gravity of the machine. Observe the road traffic regulations and
specifications of the machine manufacturer.

Maintain a distance of at least 1m to the secured edges of the pit

and a distance of at least 2m to slopes.

wz0166

BP03_082_1901EN 233
 Safetyregulations

Always make sure that there is sufficient clearance when driving

under underpasses, over bridges and through tunnels or when pas

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

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

elevated centre of gravity of the truck when travelling on a slope
and on ascending or descending routes. Always adapt your travel

ling speed to the prevailing conditions on sloping terrain.

Observe national road traffic regulations. If necessary, clean the

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

Persons accompanying the driver must be seated on the passen

ger seats provided for this purpose.

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

2.11.6 Towing The machine must only be towed, loaded and transported in ac

cordance 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.

234 BP03_082_1901EN
 Safetyregulations

2.11.7 Loading Many lifting points fitted to the machine are provided for assembly
purposes only. They are not suitable for lifting the complete ma

chine. The lifting points for lifting the entire machine are specially
marked.

wz0176

Use only appropriate means of transport and lifting equipment of

adequate load−bearing 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 load−bearing capacity

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

Secure the machine on the transport vehicle to prevent it rolling

away, slipping and toppling over.

BP03_082_1901EN 235
 Safetyregulations

2.12 Placing booms

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

structions. Stationary booms may only be raised after the proper
set−up has been checked by a subject expert.

Only raise the placing boom in the sequence described in the Op

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

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

is stopped, the entire volume of fluid is available for the remaining
movements, and can increase their speeds. Depending on the de

sign, it may be the case that carrying out several movements at
once (as opposed to carrying out a single movement at maximum
speed at any one time) does not bring any advantage in terms of
time. Carrying out several movements at once requires an in

creased level of attentiveness.

The range of a radio remote control is great enough for the machine
to receive control commands (e.g. from a great distance, from in

side enclosed spaces), even without visual contact. If there is no
visual contact, for example, because you are changing workplace,
you must switch off the remote control. If there is no visual contact,
for example, because the construction site is unclear, signallers
MUST be used, and must remain in contact with the machine oper

ator using suitable means, and have visual contact with the site of
concrete placement, work areas and danger zones, and the ma

chine.

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

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

236 BP03_082_1901EN
 Safetyregulations

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

Press the EMERGENCY STOP button immediately if the placing

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

wz0056

Placing booms with placing boom hinges which allow considerable

flex angles have a very large potential working area. This high ma

noeuvrability means different placing booms can also be moved
into dangerous positions. Prohibited areas can be found in the Op

erating Instructions.

There is a risk that you will damage the truck, truck superstructure
or obstacles on the construction site with the placing boom. Under
certain circumstances it is even possible to overload or cause dam

age to the placing boom. Uncontrolled movements may result from
the sudden, violent release of the placing boom after collisions. This
may also result in (possibly fatal) personal injury.

The manufacturer has indicated such impermissible working areas

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

BP03_082_1901EN 237
 Safetyregulations

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 accident from the end hose swinging out or stones being
ejected.

wz0136

If a longer end hose is used, the diameter of the danger zone is

also increased (see also page213).

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

The end hose must not impede the movement of the placing boom;
in particular, the end hose must not catch on the reinforcement or
formwork. There is a risk of death if the machine topples over or the
end hose shoots out on further movement of the placing boom.

238 BP03_082_1901EN
 Safetyregulations

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

ence of air in the delivery line. To prevent this from occurring, the
hopper must be filled with concrete at least as far as the agitator
shaft so that no air can be sucked in.

The end hose must be secured against falling.

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

cisely into the site of concrete placement.

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

2.12.4 Connecting drills If a drill is connected to the delivery line for the placing boom, it
must not place any further strain on the placing boom. The placing
boom must be connected to the drill in such a way that the placing
boom does not require adjustment. There should be 1−2 delivery
hoses between the placing boom and the drill; these must be se

cured so that they cannot move in an uncontrolled manner. If the
drill is moved on the construction site, the placing boom must not
be connected.

BP03_082_1901EN 239
 Safetyregulations

2.12.5 Procedure in storms Return the placing boom to the driving position or rest position in
the event of storms or bad weather.
− Placing booms with a vertical reach of 42m or more may only be
operated in winds of up to wind force7(wind speed51km/h).
− Placing booms with a vertical reach of less than 42m may only
be operated in winds of up to wind force8 (wind speed74km/h).

The definitive wind speed is measured at the height of the boom tip.

Wind speeds in accordance with the Beaufort scale are average

wind speeds measured over a period of 10minutes. Higher speed
gusts of wind may occur briefly during the measuring period.
Higher wind speeds jeopardize the stability and safety of the struc

tural elements. There is a risk of lightning strike in a thunderstorm.

Lightning strikes pose a risk of death. The machine and the sur

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

Tower cranes on construction sites generally have wind speed

measuring equipment, enabling you to find out the wind speed at
any time. If no wind speed measuring equipment is available, you
can ask the nearest meteorological office what the wind speed is, or
estimate the wind speed using the following rule of thumb:
− In winds of 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.

2.12.6 Concreting in cold The boom must not be used in temperatures below minus 15_C
weather (+5_F) unless the manufacturer has given express approval. There
is a danger of damage to the steel (brittlefracture) 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 poss

ible to prepare concrete such that it can achieve its strength without
the use of special additives.

240 BP03_082_1901EN
 Safetyregulations

2.13 Delivery line systems

2.13.1 Suitable delivery lines Only use delivery lines, end hoses, couplings, etc. which are in per

fect condition and suitable for the delivery job and have been ap

proved by the machine manufacturer. Delivery lines are subject to
wear which varies according to the delivery pressure, concrete
composition, the material from which the delivery line is made, etc.

If you are not responsible for the separate delivery lines, the per

missible operating pressures of these should be confirmed by the
operating company.

2.13.2 Securing delivery Delivery lines, delivery hoses, end hoses and couplings must be
lines securely fastened and secured to prevent spontaneous opening.

wz0066

BP03_082_1901EN 241
 Safetyregulations

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

wz0047

A properly cleaned delivery line is the best insurance against the

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

Prevent blockages by adjusting the operating conditions. Remove

blockages by reverse pumping and then restarting forward pump

ing. Repeat this process several times if necessary. If the blockage
is not removed, relieve the pressure on the delivery line before re

moving the section of delivery line concerned.

242 BP03_082_1901EN
 Safetyregulations

2.13.4 Opening delivery lines You must not open or tap delivery lines while these are pressurized.
Concrete exiting under pressure can cause injury. The concrete col

umn must be depressurized by reverse pumping before the deliv

ery line is opened. Never work bending directly over the coupling.

wz0076

2.13.5 Clearance to delivery No
one should remain in the vicinity of separate delivery lines dur

lines ing pumping operations. Cordon off the danger zone. If it is not
possible to place a large enough cordon around the danger zone,
the delivery line must be covered by suitable means.

2.13.6 Fastening delivery Delivery lines, in particular riser lines which are not laid along plac

lines ing booms, must be securely fastened in order to transfer the forces
generated in them into the structure or other structural members.
The lines must be laid so as to avoid kinks, sharp bends, stresses
and damage during pumping operations.

BP03_082_1901EN 243
 Safetyregulations

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

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

you must switch off the placing boom control system to prevent
unintended movements of the placing boom. There is a risk of acci

dent posed by jerky movements of the boom tip.

2.13.8 Devices for shutting During operation, there is a risk of being crushed and of injury by
off, diverting or clean- shearing. Hydraulically driven devices are generally supplied with
ing delivery lines power by the hydraulic system of a machine. It must therefore be
possible to see between the devices and the machine with the con

trol unit, and vice versa. Observe the Safety Manual 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.

Only use devices that are suitable and in perfect working order 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.

244 BP03_082_1901EN
 Safetyregulations

2.14 Pumping operations

2.14.1 Place of work The machine operator’s place of work is with the remote control
when the pump is in operation. If you operate the machine using
the remote control, all operating and control devices on the ma

chine must be closed to prevent unauthorized access.

In the case of stationary placing booms, platforms or similar equip

ment are only provided for assembly and maintenance work. Use of
these platforms as a place of work during operation is prohibited.

It is forbidden to climb onto the machine during operation. In the

case of stationary placing booms, it is forbidden to climb ladders
during operation.

2.14.2 Safety Before switching on or restarting the machine or individual machine

functions, you must ensure that doing so will not endanger anyone’s
safety.

Refrain from any procedures that may impair the stability of the ma

chine or are prejudicial to safety in any other way.

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

teed that you can press the EMERGENCY STOP button in the event
of an emergency situation. The EMERGENCY STOP button may
only be unlocked once the cause/emergency has been remedied.

As a general rule, you must carry the remote control so that no con

trol elements are activated unintentionally. If your attention is drawn
away from the machine (particularly when changing place of work),
you must switch off the remote control.

During breaks in pumping, interruptions, maintenance work, or be

fore you leave the machine, you must secure it to prevent unin

tended movements and unauthorized use. Switch off the remote
control and lock it away.

BP03_082_1901EN 245
 Safetyregulations

2.14.4 Moving machine com- Keep all access covers, maintenance flaps, guards, etc. closed
ponents and hot sur- and locked during operation. This also applies in particular to the
faces grille, water box cover and covers over cylinders. There is other

wise a risk of injury from moving machine components and a risk of
burning on hot surfaces. In particular, there is a risk of burning from
the engine, attached parts and the exhaust.

Never start work unless the grille is closed and bolted down or
otherwise secured.

wz0225

Do not touch moving parts of the machine, whether the machine is

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

Do not insert any objects (shovel handle, trowel, etc.) 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.

246 BP03_082_1901EN
 Safetyregulations

2.14.5 Constant observation You should be constantly observing the machine for any damage or
of the machine faults while it is in use. In the event of faults or malfunctions that im

pair safety at work, shut the machine down immediately and secure
it. Have the faults rectified immediately. If it is not possible to rectify
faults which jeopardize the safe operation of the machine, you must
suspend operations until the defects are rectified.

2.14.6 Truck mixer As the machine operator, it is your role to instruct the truck mixer
drivers who deliver the concrete to you, so that they are able to op

erate the operating elements on the concrete pump provided for
their use. Only allow the truck mixer drivers to work alone once you
are certain that they have understood your instructions.

Make sure that no−one stands between the approaching truck

mixer and the machine. There is a risk of crushing between the
truck mixer and the machine.

BP03_082_1901EN 247
 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 or
the support legs extended, even over short distances. This rule also
applies when you have to drive the machine to a different site for
cleaning. The placing boom and support legs must be fully re

tracted and secured.

wz0156

The preferred methods for cleaning the delivery line are reverse
pumping or forced cleaning with water. The agitator must be
switched on during reverse pumping. Otherwise, the concrete flow

ing back into the hopper can bend the agitator shaft. Use a catch
basket, pipe cleaning head and wash
out ball for forced cleaning to
prevent any water from flowing into the formwork.

Never spray remote controls or control cabinets with barrier agents

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

248 BP03_082_1901EN
 Safetyregulations

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.

2.15.2 Cleaning agents Take care when using aggressive cleaning agents. Aggressive
cleaning agents may attack materials (e.g.rubber) and painted sur

faces. You can use commercially available paint cleaning and care
agents, as long as these have a pHvalue of between4and9. Ask
the manufacturer of the cleaning agent to confirm its suitability. Ob

serve the manufacturer’s instructions regarding use and safe handl

ing. Wear protective clothing. Always rinse off cleaning agent thor

oughly with clean water; do not allow puddles to form.

wz0146

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

poses.

Do not use any highly flammable agent for cleaning; there is a risk
of fire.

BP03_082_1901EN 249
 Safetyregulations

2.15.3 Cleaning with com- When the delivery line is being cleaned with compressed air, there
pressed air is an increased risk of accidents caused by compressed air escap

ing explosively, spurting concrete, and delivery or end hoses mov

ing uncontrollably if they have not been removed.

Compressed air should only be used for cleaning purposes under

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

The manufacturer accepts no liability for damage caused by incor

rectly performed compressed air cleaning. If you blow out the deliv

ery line with compressed air, you must observe the following rules
without fail:
− Individual pipes and short pipe runs up to 10m in length must
not be blown through with compressed air. There is a risk of acci

dent from rebound.
− Only blow out delivery lines which have the same nominal diam

eter throughout their length. Reducer pipes must be drained and
flushed out by hand.
− No bends, delivery or end hoses may be fitted at the end of the
delivery line.
− A catch basket must be fastened at the end of the delivery line
and a wash
out adaptor must be fitted on the head of the delivery
line. Catch basket and wash−out adaptor must fit the delivery line
system.
− The concrete must be able to flow freely from the end of the deliv

ery line.
− No persons may be present in an area of 3m around the delivery
line, at the end of the delivery line and especially in front of the
opening in the catch basket.
− Care must be taken to ensure that any concrete that might be ex

pelled from the catch basket cannot injure anybody or cause any
damage.
− Separate delivery lines that are cleaned with compressed air
must be securely fastened so that they cannot move uncontrolla

bly.
− If continuing distribution systems (e.g. rotary distributors), gate
valves or other delivery line elements are connected to the deliv

ery line, they must be secured in such a way that they cannot
move in an uncontrolled manner.

250 BP03_082_1901EN
 Safetyregulations

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

cock and a pressure gauge.
− The pressure gauge must be kept under constant observation
during the cleaning process. The pressure in the delivery line
must be rapidly dumped via the dump cock in the event of a
sudden drop in pressure (concrete column exiting from the end
of the line) or increase in pressure (risk of blockage).
− The sponge ball or the plug used to push the concrete out must
be sufficiently dense that the air does not pass through it into the
concrete. In addition, the delivery line must be sealed to the rear
when the sponge ball or plug is caught in the catch basket.
− Only work on the delivery line (particularly when opening the de

livery line) if it has been depressurized. Make sure that the com

pressed air has been dumped completely.
− The dump cock must be opened in such a way that no−one can
be injured by concrete residue that might be expelled from the
dump cock.

2.15.4 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 cabi

nets are particularly at risk.

2.15.5 Post–cleaning pro- After the machine is cleaned, the covers/tapes must be completely
cedure removed and the machine must be checked to ensure that it is
ready for operation (seealso page221).

Look out for leaks, loose connections, chafe marks and damage
during the cleaning procedure. Any identified defects must be recti

fied immediately. The machine must be greased after it has been
cleaned using a high
pressure cleaner.

BP03_082_1901EN 251
 Safetyregulations

252 AusgleichsseiteEN
 Generaltechnicaldescription

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 3I
 Generaltechnicaldescription

3II BP02_001_0302EN
 Generaltechnicaldescription

3.1 Overview Below you will find an overview of the components that are de

scribed on the following pages.

Left-hand side

1 2 3 4 5 6 7 8

16 15 11 14 13 12 11 10 9
AP02_967_1509EN 1

No.0 Component Page

1 Documentation accompanying the machine −
2 Engine (see manufacturer’s documentation) −
3 System for exhaust gas treatment 3110
4 Hydraulic pumps −
Condition of the suction filter 3103
5
Suction filter 3103
6 Pressure filter 3103
7 Hydraulic fluid reservoir −
8 Fuel tank −
9 Pressure connection −
10 Agitator safety cutout 393
11 Support leg with support foot −
Flushing water pump 3107
12
Water pump lever 3100
13 Centralized lubrication system (optional) 319
14 Battery −
15 Support wheel −
16 Towing ring −

AP02_967_1509EN 31
 Generaltechnicaldescription

Right-hand side

1 2 3

11 10 9 8 7 6 5 4
AP02_967_1509EN 2

No.0 Component Page

1 Central module control cabinet 323
2 Hydraulic indicators 3103
3 Remote control 387
4 Machine rating plate 37
5 DEF container (see manufacturer’s documentation) −
6 Magnetic switch distributor casing 395
7 Buzzer −
Control block −
8 Delivery cylinder emergency control lever 3101
Transfer tube change−over valve 3101
9 Connection for remote control −
10 Operating panel 389
11 Centralized lubrication system 319

32 AP02_967_1509EN
 Generaltechnicaldescription

3.2 Safety equipment This illustration shows examples of safety equipment which may be
fitted on the machine.

1 2 3 4 5

13 12 11 10 9 8 7 6
AP02_330_0904EN 1

No. 0 Safety equipment

1 EMERGENCY STOP button / STOP button on the remote control
2 Covers over the switch cylinders
3 Side protection doors
4 Exhaust guard
5 Safety grille on the V−belt
6 Transport protection
7 Securing bolts/spring pins on the support leg
8 Hydraulic/mechanical set−up foot
9 Water box cover
10 Toggle switch for Local control − 0 − Remote control
11 EMERGENCY STOP button on the operator’s side
12 Engine stop
13 Agitator safety cutout
→

AP02_330_0904EN 33
 Generaltechnicaldescription

14

15

16

AP02_330_0904EN 2

Continued
No. Safety equipment
14 Sound proofing equipment/sound proofing kit
15 Spray guard
16 Grille on the hopper

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

Check the safety equipment as described in the Operating Instructions.

34 AP02_330_0904EN
 Generaltechnicaldescription

3.3 Technical data You will find the most important technical data and setting values for
your machine in the following table, and also in the test reading de

livered with your machine and on its rating plate.

BSA model 1409 D

Height 2510 mm
Dimensions Length 5750 mm
Width 2020 mm

Performance data
Main pump hydraulic fluid pressure 360 bar
Maximum concrete pressure − rodside 71 bar
Maximum concrete pressure − pistonside 106 bar
Maximum output − rodside 97 m3/h
Maximum output − pistonside 67 m3/h
Min./max. theoretical strokes under no load − rodside 37 1/min
Min./max. theoretical strokes under no load − pistonside 25 1/min
Control voltage 24 V

Settings
Switch
off temperature for hydraulic fluid 90 _C
Accumulator pre
charge pressure 90 bar

Capacities
Hydraulic fluid reservoir 150 litres
Fuel tank 120 litres

AP02_968_1410EN 35
 Generaltechnicaldescription

3.3.1 Electromagnetic The machine in question meets the requirements set out in Appendix
compatibility (EMC) 1 of Directive 2014/30/EU of the European Parliament and of the
Council of 26 February 2014.

The electromagnetic compatibility has been tested and meets the

requirements set out under EN 13309:2010−12.
Test report number: P150760
The machine can be used in residential areas without restriction.

36 AP21_056_1604EN
 Generaltechnicaldescription

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

1 Betonpumpe
2 BSA 1409 D4

3
210110932
4 6

7 8

BP22_830_1005EN 1

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

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

BP22_830_1005EN 37
 Generaltechnicaldescription

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

The place of work is from the remote control. The machine has a
sound pressure level of 85 dB(A) within a radius of 16m. Ear de

fenders must be worn in the vicinity of the machine since the sound
pressure level can be higher. The sound pressure was determined
on the basis of Directive 2000/14/EU.

3.3.4 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.

123
BP21_359_1001EN 1

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

38 BP21_359_1001EN
 Generaltechnicaldescription

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

Sound pressure level In the past, the sound pressure level of the machine was stated. To
measure this level, the sound produced by the machine was
measured at several measuring points and at a fixed distance and
height. The average value was determined from these measure

ments and converted to a theoretical distance. The sound pressure
level stated for the machine therefore always referred to a theoretical
distance and was given in dB(A).

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

closer to the machine.

Sound power level Nowadays, the sound power level of the machine is stated. To calcu

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

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

sure level increases, the surface area of the imaginary sphere de

creases. This means that multiplying the two figures gives the same
sound power level as before.

BP21_359_1001EN 39
 Generaltechnicaldescription

3.4 Description of the This chapter is intended to help you understand the operational
functions sequences of the machine so that you can limit the field of the
machine’s applications to suitable areas and avoid errors in
operation.

3.4.1 Chassis Your machine may be mounted on different chassis models or on

astatic base structure, depending on the equipment. The chassis
model is stated on the machine card and the maximum permitted
speed is stated on the rating plate.

F 8 chassis Your machine can be towed by a tractor unit if fitted with an

F8chassis. The chassis is unbraked and is designed for a maxi

mum speed of 8km/h only. The machine may therefore only be
towed by a tractor unit on the construction site.

Note
The machine is neither equipped nor approved for travel on public
roads.

F 25 chassis Your machine can be towed by a tractor unit if fitted with an

F25chassis. The chassis is unbraked and is designed for a maxi

mum speed of 25km/h only. The machine may therefore only be
towed by a tractor unit on the construction site.

Note
The machine is neither equipped nor approved for travel on public
roads.

310 AP02_004_1211EN
 Generaltechnicaldescription

F 80 chassis The machine may travel on public highways in the same way as a
standard trailer if fitted with an F80 chassis.

Note
Trailer concrete pumps may only use public roads if properly
approved.

Crawler track Your machine can be towed by a tractor unit if fitted with a crawler
track.

Note
Observe the manufacturer’s operating and maintenance instructions.

The machine is neither equipped nor approved for travel on public

roads.

3.4.2 Static base structure If your machine is fitted with a stationary base structure, it can only
be moved to the construction site on a transport vehicle.

3.4.3 Support legs The support legs give the stability required. They are manually
adjustable.

AP02_004_1211EN 311
 Generaltechnicaldescription

3.4.4 Pump

1
2
3

6
7
AP02_004_1211EN 1

No.0 Designation
1 Piston rod
2 Water box
3 Delivery piston
4 Delivery cylinder
5 S transfer tube
6 Pressure connection
7 Delivery line

Putzmeister pumps are driven hydraulically by diesel engines or

electric motors acting through fluid pumps. The delivery pistons(3)
are connected to the piston rods(1) of the drive cylinders by way of
intermediate flanges. The drive cylinders are extended and retracted
hydraulically and thus push the delivery pistons(3) forwards and
backwards in the delivery cylinder(4). The drive cylinders are
hydraulically coupled together so that they run in counter stroke.

312 AP02_004_1211EN
 Generaltechnicaldescription

S transfer tube The Stransfer tube(5) is built into the hopper on the pump. Its wear
ring locates against the spectacle wear plate. Its other end is fitted in
the pressure connection(6) to which the delivery line is connected.
The transfer tube(5) is switched across by two switch cylinders.

Water box The water box(2) is fitted between the drive cylinders and the
delivery cylinders. The water in the water box performs the following
functions:
− it cools the delivery pistons and the piston rods;
− it rinses the inner wall of the delivery cylinders.

Pumping The returning delivery piston sucks the medium in from the hopper.
At the same time, the advancing delivery piston forces the medium
which has previously been sucked in through the transfer tube into
the delivery line.

At the end of the stroke, the pump switches over, i.e. the transfer
tube is swung in front of the full delivery cylinder and the delivery
pistons reverse their direction of movement.

Change-over Reversal of the delivery pistons’ direction in the middle of the stroke
movement. The transfer tube switches over. The medium is still
pumped without interruption. Changing the stroke over helps prevent
the formation of a blockage.

Reverse pumping The delivery pistons reverse their direction during the stroke move

ment for reverse pumping. The transfer tube does not switch over so
the pump now runs in reverse. The medium is sucked from the deliv

ery line and pumped back into the hopper and the pressure in the
delivery line is dumped.

AP02_004_1211EN 313
 Generaltechnicaldescription

3.4.5 Transfer tube damping The transfer tube is switched more slowly when transfer tube
damping is switched on (lever on the snail symbol), this protects the
switching mechanism for the transfer tube. Transfer tube damping
can however only be used if the concrete is very fluid and must only
be pumped at low concrete pressure.

Transfer tube damping valve

Note
The transfer tube must switch over rapidly when pumping to great
heights so that the switchover pauses are a short as possible. The
concrete column in the delivery line pushes back onto the concrete
pump if there are lengthy switchover pauses.

You should set the transfer tube damping lever to the
Hare" symbol
for rapid switch over.

314 AP02_015_9604EN
 Generaltechnicaldescription

3.4.6 Agitator The hopper is equipped with a hydraulically driven agitator. The
agitator performs two functions:
− it improves the filling rate of the delivery cylinders;
− it mixes the concrete.

AP02_055_9710EN 1

No0 Designation
1 Hydraulic motor
2 Agitator shaft
3 Agitator helix

Improving the The filling rate in the delivery cylinders should be as high as possible
filling rate when pumping. This is achieved by having the agitator helix mix to

wards the delivery cylinders.

Mixing the concrete The concrete should be mixed following reverse pumping from the
delivery line into the hopper. This is achieved by having the agitator
helix mix away from the delivery cylinders.

AP02_055_9710EN 315
 Generaltechnicaldescription

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

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

Truck-mounted concrete pump standard

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

Truck mixer concrete pump standard

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

stationary concrete pump standard

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

316 BP22_827_1212EN
 Generaltechnicaldescription

3.5.2 Site of use A concrete pump is designed for industrial use on outdoor construc

tion sites, or indoors with adequate ventilation. It must not be used in
areas where there is a potentially explosive atmosphere.

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

Pump type maximum height

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

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

BP22_827_1212EN 317
 Generaltechnicaldescription

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

temperature outside the given temperature ranges.

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

*Limited due to the diesel engine without pre
heating device. When

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

318 BP22_827_1212EN
 Generaltechnicaldescription

3.5.5 Centralized The centralized lubrication system comprises a lubricant pump /

lubrication system grease gun, lubricant distributors, relief valves and supply lines.

1a

1b

3 3

4 4

5
8 9 8

6
AP02_789_1009EN 1

No.0 Designation
1a Lubricant reservoir
1b Lubricant pump
2 Grease gun
3 Lubricant distributor
4 Agitator shaft bearings
5 Transfer tube bearing
6 Supply lines from the dry running cut
out lubricant distributor
7 Upper switch cylinder bearings
8 Lower switch cylinder bearings
9 Switching shaft bearings

AP02_789_1009EN 319
 Generaltechnicaldescription

The centralized lubrication system supplies the connected lubrica

tion points with grease and hydraulic fluid. The lubrication points are
lubricated in fixed cycles.

Lubricant reservoir The lubricant reservoir may be filled up to the Max"marking through
the filling nipple or from above through the filling opening.

Note
Note the following when filling the lubricant reservoir:
 Use only a grease listed in the lubricant recommendation table.
 Never fill the reservoir above the MAXmark.
 Never pump the reservoir dry.
 Switch off the power supply before filling the reservoir from above.

Grease gun The grease gun can be used to manually distribute grease to the
lubrication points.

320 AP02_789_1009EN
 Generaltechnicaldescription

3.5.6 Dry running cut-out The dry running cut
out comprises a lubricant distributor and the
lines to the lubrication points. The lubricant distributor inlets are
connected to the hydraulic circuit of the switch cylinders.

Lubricant distributor
1 2

AP02_789_1009EN 2

No. 0 Designation
1 Inlet
2 Outlets

Each time the Stransfer tube switches over, the lubricant distributor
releases a drop of hydraulic fluid alternately through the upper or
lower outlets to the lubrication points connected.

The dry running cut
out supplies:

− the delivery cylinder pistons
− the switching shaft bearing
− the transfer tube bearing
− the agitator shaft bearings

Note
Some hydraulic fluid will always gets into the water box because of
the dry running cutout for the delivery cylinder pistons.

AP02_789_1009EN 321
 Generaltechnicaldescription

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

trol 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
− cable remote control
− radio remote control
− distributor casing for magnetic switch

Note
Further control devices and components are described in the

Hydraulic control devices" (from page 399) and
Other
components" (from page 3105) sections.

322 AP02_057_9801EN
 Generaltechnicaldescription

3.6.1 Central module con- On the central module control cabinet, you can control the functions
trol cabinet of the pumps and the systems for exhaust gas treatment and detect
the operating states of the machine and the exhaust after treatment
system.

6 5 4

AP02_969_1508EN 1

Pos. Operating/ Belongs

Meaning/function
0 control element to pos.:
1 Ergonic Graphic Display Displaying and setting operating states
2 Toggle switch Regeneration: On  Off
Toggleswitch, lo
Pumping operations/approval of regener

3
callylatched ation
4 Toggle switch Engine protection override
5 Bush Diagnosis
6 Ignition−starter switch Engine: On  Off

AP02_969_1508EN 323
 Generaltechnicaldescription

Right–hand view

AP02_969_1508EN 2

Operating/
Pos. 0 Meaning/function Comments
control element
1 Power socket, 1
pin Connection for working light optional
2 Round socket, 4
pin Connection for vibrator optional
3 Locally latched toggle Localcontrol− 0− Remotecontrol
switch
4 Bush Connection for remote control

324 AP02_969_1508EN
 Generaltechnicaldescription

Special features of the control cabinet

Closing and locking the The control cabinet is located in a stowage compartment. You must
control cabinet keep this stowage compartment locked at all times to prevent un

authorized persons from switching the control system over.

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

Diagnostics socket A diagnostics unit can be connected to the diagnostics socket by

authorized and qualified personnel in order to collect data from the
machine.

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

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

Engine protection over You can only use the motor protection override to override faults that
ride toggle switch are relevant to the engine (e.g. coolant level too low, water volume in
fuel too high, etc.). Faults in the exhaust after treatment (EAT) cannot
be overridden using the override.

Note
If the engine overheats, it automatically switches off (see the
Engine
status" symbol in the Ergonic Graphic Display (EGD) of the central
module control cabinet).
In emergency operation, the
Engine protection override" switch
must be permanently held down by hand when switching on and
continuing to run the engine.

AP02_969_1508EN 325
 Generaltechnicaldescription

Note
Abbreviations used:
EAT = Exhaust After Treatment (exhaust gas treatment)
DEF = Diesel Exhaust Fluid (urea solution used in exhaust gas treat
ment, e.g.
AdBlue")
*DPF = Diesel Particle Filter
*DOC = Diesel Oxidation Catalyst
*SCR = Selective Catalytic Reduction

* = Machine−specific

Note
When the
Regeneration" warning symbol lights up yellow in the
EGD of the central control cabinet, you must
manually" start the re
generation procedure/stationary regeneration.
The regeneration procedure can only be started
manually" if the fol
lowing conditions are met:
 You have positioned the machine in the open, in an area with suffi
cient distance from other machines, combustible materials and
flammable liquids.
 The engine speed must be reduced to idling speed.
 The delivery rate must be reduced to 0%.
 The engine must be in a no−load state.
 The engine must be warm (coolant temperature higher than 70°C
and exhaust gas temperature downstream of the DOC lower than
250°C).
 The SCR system for reducing nitrogen oxide (NOx ) must be active.
 The
Fill level of the DEF container" warning symbol must display a
level greater than 15%.
 The DEF container must not be frozen.

If all of the above−mentioned conditions have been met, you can

start the regeneration procedure at the central module control cabi
net.
The regeneration procedure lasts up to 40 minutes and takes place
at exhaust gas temperatures of approx. 600°C at the exhaust gas tail
pipe.

326 AP02_969_1508EN
 Generaltechnicaldescription

Manually switching on Switch on the regeneration procedure on the central module control
the regeneration pro cabinet as follows:
cedure − Switching the toggle switch from Pumping operation" to Enable
regeneration" interrupts the pumping operations and enables the
regeneration procedure. The EMERGENCY STOP status is trig

gered at the same time.
− Switching the toggle switch to Regeneration On" starts the regen

eration procedure.

Starting up the pump Once the regeneration procedure is complete, you can only start up
after the regeneration the pump again by following the procedure described below:
procedure − On the central module control cabinet, switch the toggle switch
from Enable regeneration" to Pumping operations".
− Press the Deactivate EMERGENCY STOP" toggle switch on the
remote control.
− Press the Acknowledge agitator safety cutout" toggle switch in
the operating panel.
− Press the Pump On" toggle switch on the remote control.

AP02_969_1508EN 327
 Generaltechnicaldescription

Manually switching off Switch off the regeneration procedure on the central module control
the regeneration pro cabinet as follows:
cedure − Pressing the toggle switch RegenerationOn−Off" again inter

rupts the regeneration procedure or stops the procedure.
− Switching the Pumping operations/Enable regeneration" toggle
switch from the Enable regeneration" switch position to the
Pumping operations" switch position interrupts the regeneration
procedure or stops the procedure.

We recommend that you do not interrupt the regeneration procedure.

The number of interrupted regeneration procedures is logged in the
control unit.

Note
If you interrupt a regeneration procedure due to a yellow
Regener
ation" warning symbol, the exhaust after treatment system will acti
vate further escalation levels (depending on the length of the pump
ing operation).
The result is that power reduction level2 is activated in the last es
calation level if there is a red
Filter maintenance required" warning
symbol. Pumping operations and regeneration are no longer poss
ible.
*A service employee from the engine manufacturer must replace the
DPF filter.
*The engine can only be enabled using service software from the en
gine manufacturer (SERDIA service tool).

*Machine−specific

328 AP02_969_1508EN
 Generaltechnicaldescription

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

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

Colour / Appearance Meaning

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

ency operation.

BP22_949_1104EN 329
 Generaltechnicaldescription

EGD and operating

elements

3
1

5 5 5
BP22_949_1104EN 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 HOME" function key
3 Push
button Help" function key
Function button F4 for selecting or setting symbols and
4 Rotary/push
button
numerical values.
5 Push
button Function buttons F1, F2, F3 for navigating between
menus

330 BP22_949_1104EN
 Generaltechnicaldescription

Using the menus

The HOME" function key takes you back to the HOME" menu from
any of the sub
menus.

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

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

Use the rotary push−buttonF4 to set the functions that can be se

lected, as follows:

Note
In the Pump Status, Pump Settings and Pump Counter menus, you
can select some functions and sensors (using F4). The functions and
sensors selected have a red border.

" Turn F4 to select a function.

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

" Then press F4 to activate the selected function.

å The function flashes or appears purple.

" Now turn F4 to change the settings.

" Press F4 to store the changed setting.

AP02_978_1411EN 331
 Generaltechnicaldescription

Menu structure The following pages show the password−free section of the menu
structure (example). When the machine is set up, HOME" is dis

played as the start screen for 5seconds.

1 3

6 7 8

9 10

AP02_970_1410EN 1

332 AP02_970_1410EN
 Generaltechnicaldescription

See
No. 0 Display Function/meaning
page
Displayed for 5seconds once the ignition is
1 Test screen
switched on.
2 HOME Data display 335
Press HOME" in HOME to display the Info"
3 Info 372
menu.
Press Help" in HOME to display the menu
4 Help
structure.
Press F4 in HOME to display the Service"
5 Service 371
menu.
Press F1 in HOME to display the
6 Pump status 341
Pumpstatus" menu.
Press F2 in HOME to display the Pump
7 Pump settings 347
settings" menu.
Press F3 in HOME to display the Pump flow
8 Pump flow meter 359
meter" menu.
Press F1 in the Pump flow meter" menu to
9 Engine diagnosis 365
display the Engine diagnostics" menu.
Press F2 in the Pump flow meter" menu to
10 Fault memory 370
display the Fault memory" menu.

AP02_970_1410EN 333
 Generaltechnicaldescription

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

1 2

BP22_944_1104EN 1

No. 0 Display Function / meaning

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

334 BP22_944_1104EN
 Generaltechnicaldescription

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

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

3 4 5

2 7

9
10

11

1 12
13

17 16 15 14
AP02_971_1501EN 1

Pos.
Display Function/meaning
0

The temperature of the hydraulic fluid is displayed in

1 Temperature, digital
numbers.
The temperature of the hydraulic fluid is displayed
2 Temperature, analogue
graphically.
3 Power input, digital The current power input for the core pump is dis

played in numbers.
4 Power input, analogue The current power input for the core pump is dis

played graphically.
5 Maximum power input, digi
The maximum possible power input for the hydraulic
tal pump is displayed in numbers.
→

AP02_971_1501EN 335
 Generaltechnicaldescription

3 4 5

2 7

9
10

11

1 12
13

17 16 15 14
AP02_971_1501EN 2

Continued
Pos. Display Function/meaning
6 Operating hours meter The machine operating hours are displayed.
7 Stroke counter The total strokes for the machine are displayed.
The current concrete pressure is displayed in
8 Concrete pressure, digital
numbers.
The current concrete pressure is displayed graphically.
Concrete pressure, ana

9 The scale for the graphic display ranges from 0 to the
logue
maximum possible concrete pressure.
Maximum concrete pres
The set concrete pressure limit is displayed in
10
sure, digital numbers (see the Pump settings" menu).
11 Delivery rate, digital The current delivery rate is displayed in numbers.
The current output is displayed graphically. The scale
12 Output, analogue for the graphic display ranges from 0 to the maximum
possible output.
The set output restriction is displayed in numbers (see
13 Maximum output, digital
the Pump settings" menu).
→

336 AP02_971_1501EN
 Generaltechnicaldescription

3 4 5

2 7

9
10

11

1 12
13

17 16 15 14
AP02_971_1501EN 3

Continued
Pos. Display Function/meaning
Navigation symbol and Press F4 to display the Service" menu.
14
Service" menu
15 Navigation symbol Press F3 to display the Pump flow meter" menu.
The Local control
0
remote control" switch setting
Navigation symbol and se

16 is displayed.
lected control mode
Press F2 to display the Pump settings" menu.
The pump off", pump on" and reverse pumping"
Navigation symbol and se

17 functions are displayed.
lected pump function
Press F1 to display the Pump status" menu.

AP02_971_1501EN 337
 Generaltechnicaldescription

Special features of the displays in the “HOME” menu

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

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

Output display The output value is calculated from the stroke time and the geo

metric data of the delivery cylinders at a fill level of 100 %. When
theconcrete pump is switched off, the value 0" is displayed.

338 BP22_300_0704EN
 Generaltechnicaldescription

Symbols for the “HOME” menu

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

Warning
Symbol lights up yellow if a limit has been reached, for example.

Agitator safety cutout

Symbol lights up red if the agitator safety cutout has been activated.

EMERGENCY STOP
The symbol lights up red if an EMERGENCY STOP button has been
operated.

Tank reserve (optional)

Symbol lights up yellow if the tank content has fallen to less than
15%.

Hydraulic fluid radiator

Symbol lights up green if the hydraulic fluid radiator is switched on.
(see Symbols for the Pump Settings menu")

Engine status
Symbol lights up red if there is a fault on the diesel engine (see the
Pump Status" menu or documentation from the engine manufac

turer).

Pump centralized lubrication system

Symbol lights up red if there is a fault on the centralized lubrication
system or a lubricant reservoir is empty (see Symbols for the Pump
Settings menu").
The symbol lights up green during the lubrication procedure.

AP02_972_1704EN 339
 Generaltechnicaldescription

Fill level warning symbol for the DEF container (green)

Symbol lights up dark green if the fill level in the DEF container is
>15%, and light green if the container content is between <15% and
>10%.

Fill level warning symbol for the DEF container (yellow)

This symbol lights up yellow if the container content is between
<10% and >5%. The relevant message text is also displayed in the
EGD.

Fill level warning symbol for the DEF container (orange)

This symbol lights up orange if the container content is between
<5% and >2.5%. The relevant message text is also displayed in the
EGD. Power reduction stage 1 is activated.

Fill level warning symbol for the DEF container (red)

This symbol lights up red if the container content is between <2.5%
and 0%. The relevant message text is also displayed in the EGD.
Power reduction stage 2 is activated.

340 AP02_972_1704EN
 Generaltechnicaldescription

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

1 2 3 4 5

6
AP02_973_1508EN 1

Pos.
Display Function/meaning
0

Animated representation of the pumping process in

1 Animation
real time (example shown here).
2 Delivery direction An arrow indicates the direction of delivery.
3 Transfer tube The switchover procedure is displayed graphically.
The current that controls the swashplate valve is dis

4 Ammeter
played.
Grey: Magnetic switch is OK.

Green: Magnetic switch has switched during the

switchover procedure.
5 Magnetic switch status Red: Magnetic switch has not sent a signal. Mag

netic switch or cable defective.

Blue: Magnetic switch that is actuated first.

AP02_973_1508EN 341
 Generaltechnicaldescription

1 2 3 4 5

6
AP02_973_1508EN 2

Continued
Pos. Display Function/meaning
6 High pressure The high pressure of the hydraulic fluid is displayed.
7 Number of strokes The number of strokes per minute is displayed.
8 Stroke time The current stroke time is displayed.
9 Engine speed The current engine speed is displayed.

Special features of the displays in the “Pump status” menu

Number of strokes and The number of strokes and stroke time are not displayed until the
stroke time transfer tube has switched once. When the concrete pump is
switched off, the value0" is displayed.

342 AP02_973_1508EN
 Generaltechnicaldescription

Symbols for the “Pump status” menu

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

Engine speed
Symbol flashes if there is no speed of rotation signal (e.g.engineoff,
engine speed sensor on engine is defective, concrete pump is
switched on and engine speed is too low for pumping).
You can switch off the sensor (seepage346).
− The engine speed must then be adjusted manually.
− The EOC function is switched off.
− The engine speed is not limited.
− The EPS control system calculates the deflection angle of the hy

draulic pump using only the maximum engine speed.
− The delivery rate is then dependent on the deflection angle of the
hydraulic pump and the actual engine speed.

Transfer tube
Symbol flashes if the resolver on the switching shaft is defective.
You can switch off the sensor (seepage346).

Magnetic switch
Symbol flashes if one of the magnetic switches on the drive cylinders
is defective.
You can switch off the sensor (seepage346).
This activates the emergency controls which allow the pumping pro

cess to continue with restricted functionality.

AP02_974_1410EN 343
 Generaltechnicaldescription

Hydraulic fluid overheating

This symbol flashes if the temperature sensor in the leakage oil line
of the main hydraulic pump measures at least 85°C or is defective.
Then the delivery rate is gradually reduced to 20%, and the Warn

ing" symbol lights up yellow in the HOME" menu.
You can switch off the sensor (seepage346).
This reduces the delivery rate to 50% and the hydraulic fluid radiator
fans are switched on if the engine is running.

Cause of pump stoppage

Symbol flashes if the pump has been stopped due to a fault. In addi

tion, the cause of the last pump stop is displayed (see the following
table).

Fault code Meaning

1 Agitator safety cutout
2 EMERGENCY STOP
4 Pump stop" momentary
contact switch
8 Engine speed
16 Lower fill
level sensor
32 Pump centralized lubrication system
64 Excess temperature
128 External stop
256 Short circuit
512 Transfer tube sensor
1024 Pressure sensor
2048 Gate valve closed
4096 Stroke count reached

344 AP02_974_1410EN
 Generaltechnicaldescription

High pressure
Symbol flashes if the pressure sensor on the main hydraulic pump is
defective.
You can switch off the sensor (seepage346).
This automatically limits the delivery rate to 50%. The pump settings
are automatically set to the factory values.

Output current monitoring

Symbol lights up red if there is a fault on a monitored outlet. In addi

tion, the number of the defective outlet is displayed (see the follow

ing table).
It is possible, for instance, that the magnetic coil of a hydraulic valve
is defective. This means that the associated outlet will be automati

cally switched off.
You can then continue to pump in emergency operation.

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

Pump centralized lubrication system

Symbol lights up red if there is a fault on the centralized lubrication
system or a lubricant reservoir is empty (see Symbols for the Pump
Settings menu").
Symbol lights up green during the lubrication procedure.

AP02_974_1410EN 345
 Generaltechnicaldescription

Overriding sensors If a sensor signal that transmits data relevant to the pump control
system fails, sensors can be overridden if you switch off the sensor.
The following displays are possible:

Sensor ... working defective switched off

Symbol normal flashing cancelled
Symbol green or yel
red normal
low

Possible causes of absence of sensor signals:

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

These sensors can be switched off (depending on the machine

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

To switch off the sensors using function buttonF4:

− Turn F4 to select a function.
å The symbol either appears in a red frame, or lights up red.
− Then press F4 to activate the selected function.
å The symbol flashes or turns purple.
− Now turn F4 until the symbol appears crossed out or the colour
changes.
− Press F4 to store the changed setting.
å The symbol has a red frame or appears in a different colour.

346 AP02_976_1508EN
 Generaltechnicaldescription

“Pump settings” menu In this menu, you can set the machine’s performance data and oper

ate some of the machine’s functions from the control cabinet. In this
menu, the function buttons have the following functions:
− F1 = select from between engine speed (rpm), delivery rate or
stroke count
− F2 = reduces the parameter value, depending on what was se

lected (engine speed (rpm), delivery rate or stroke count)
− F3 = increases the parameter value, depending on what was se

lected (engine speed (rpm), delivery rate or stroke count)
− F4 = Adjust settings, switch functions on or off

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

The following settings are programmed at the works:

 Concrete pressure = 100%
(restricted to 85bar for piston side drive)
 Delivery rate = 100%
 External service operation (*)
 External EOC (*)
 POHOn (*)
 Hydraulic fluid radiator AUTO (*)

AP02_977_1411EN 347
 Generaltechnicaldescription

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

Hydraulic fluid radiator The hydraulic fluid radiator is set to AUTO" at the works. If the hy

draulic fluid reaches the temperatures preset in the hydraulic fluid
radiator control system, the fan(s) are switched on automatically.

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

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

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

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

Switching between rod If the machine is equipped with rod side − piston side feed switch

side and piston side ing, then this is described on the following pages.
feed

348 AP02_977_1411EN
 Generaltechnicaldescription

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

1 2 3 4 5 6 7

13 12 11 10 9 8
AP02_977_1411EN 1

No. 0 Display Function/meaning

Concrete pressure limit, The set concrete pressure limit is shown graphically,
1
analogue and can be adjusted using the rotary push−buttonF4.
Concrete pressure limit, The set concrete pressure limit is displayed in
2
digital numbers.
Delivery rate restriction, The set delivery rate restriction is shown graphically,
3
analogue and can be adjusted using the rotary push−buttonF4.
Delivery rate restriction, The set delivery rate restriction is displayed in
4
digital numbers.
→

AP02_977_1411EN 349
 Generaltechnicaldescription

1 2 3 4 5 6 7

13 12 11 10 9 8
AP02_977_1411EN 2

Continued
No. Display Function/meaning
The date and time appear, and can be adjusted using
5 Date / time
the rotary push−buttonF4.
Symbol lights up red if the agitator safety cutout has
6 Agitator safety cutout
been activated.
The symbol lights up red if an EMERGENCY STOP but

7 EMERGENCY STOP
ton has been operated.
In the case of local control, the setpoint value of the
8 Delivery rate, digital
delivery rate is shown in numbers as a percentage.
By pressing F3, you can increase the parameter value,
9 Symbol +" depending on what was selected (engine speed
(rpm), delivery rate or stroke count).
10 Engine speed The current engine speed is displayed.
11 Stroke counter The current number of strokes is displayed.
By pressing F2, you can reduce the parameter value,
12 Symbol −" depending on what was selected (engine speed
(rpm), delivery rate or stroke count).
Engine speed (rpm)
By pressing F1 repeatedly, you can choose from en

13 Delivery rate
gine speed (rpm), delivery rate or stroke count.
Stroke counter

350 AP02_977_1411EN
 Generaltechnicaldescription

Symbols for the “Pump settings” menu

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

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

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

EMERGENCY STOP
The symbol lights up red if an EMERGENCY STOP button has been
operated.

Agitator safety cutout

Symbol lights up red if the agitator safety cutout has been activated.

Deactivate EMERGENCY STOP

The Deactivate EMERGENCY STOP" symbol can be selected. By
using the F4 function button to select and press this symbol, you can
deactivate the EMERGENCY STOP circuit.

AP02_979_1501EN 351
 Generaltechnicaldescription

Centralized lubrication system

The symbol lights up green during the lubrication procedure.
You can start a manual lubrication procedure by using the F4 func

tion button to select and press the symbol.
The symbol lights up red if there is a fault on the centralized lubrica

tion system or a lubricant reservoir is empty.

Caution
Damage to the lubricated bearings caused by increased wear, if ma
chine operation is continued during failure of the centralized lubrica
tion system.
Operating the machine with a defective centralized lubrication sys
tem (which results in wear) leads to a loss of warranty or guarantee
claims.
Do not operate the machine if the display indicates a fault in the cen
tralized lubrication system.

Note
The number of operating hours (in the case of a defective central
ized lubrication system) is recorded in the system.
The red centralized lubrication system symbol is displayed perma
nently until the fault is rectified.
Rectify the fault in the centralized lubrication system as follows:
 Fill the empty lubricant reservoir.
 Initiate a manual lubrication procedure.
 If the red
Centralized lubrication system" symbol lights up again
after a short time, you must start another manual lubrication pro
cedure.
The red
Centralized lubrication system" symbol in the
HOME"
menu goes out. If there is no fault, the
Centralized lubrication sys
tem" symbol lights up green.

352 AP02_979_1501EN
 Generaltechnicaldescription

EOC (Ergonic Output Control), (optional)

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

Stroke counter
The current number of strokes is shown next to the symbol.
You can reset the stroke counter to0" by selecting the symbol with
the F4 function button and pressing it.

Push Over (optional)

The function can be switched on/off(I/0) or switched to External"
using the function buttons.
When you switch on the PushOver function, the delivery piston starts
up quicker after the switch over. This shortens the interruptions in
delivery and there is only a minimal break in the output flow rate.
When you switch off the PushOver function, the delivery piston ac

celerates evenly at the start of the stroke. This pushes the concrete
more gently. The interruptions in delivery at the switch over are mar

ginally longer.

AP02_979_1501EN 353
 Generaltechnicaldescription

SBU (switching between rod side and piston side feed) (op-
tional)
The pump control system must be set using the function buttons in
such a way that it matches with the type of drive for the delivery cyl

inder. The pump control system can be switched over using the
function buttons.

Conveying
Symbol appears if the concrete pump is switched over to forward
pumping or reverse pumping. The operation mode can be switched
over using the function buttons (forward pumping/reverse pumping).

Hydraulic fluid radiator (optional)

Symbol lights up green if the hydraulic fluid radiator is switched on.
The operation mode for the hydraulic fluid radiator can be selected
using the function buttons (AUTO / ON).

354 AP02_979_1501EN
 Generaltechnicaldescription

Switching between On some construction sites, it is necessary to pump as much con

rod side and piston crete as possible in a short time (rod side feed). On other construc

side feed tion sites, on the other hand, it is necessary to pump the concrete as
far or as high as possible (piston side feed). You can convert the ma

chine to meet the requirements of the construction site in a few ac

tions.

Definition What is rod side drive/piston side drive?

Rod side In the case of rod side pressurizing, the hydraulic cylinder is filled
with a small volume of hydraulic fluid (cylinder volume minus rod vol

ume). Since the cylinder is filled quickly, the concrete pump runs
more quickly and the delivery rate is greater. The hydraulic pressure
is, however, distributed over a smaller surface area (piston surface
area minus rod surface area), i.e. the force obtained is less.

Piston side The full volume of the cylinder is filled with hydraulic fluid in the case
of piston side feed. Filling takes longer, i.e. the concrete pump runs
more slowly and the delivery rate is less. The hydraulic pressure is
distributed over a greater surface area (entire surface area of the
piston), i.e. the force obtained is greater.

AP02_980_1411EN 1

Rod side feed Piston side feed

AP02_980_1411EN 355
 Generaltechnicaldescription

Switching over the The pump control system must be set using the function buttons in
pump control system such a way that it matches with the type of drive for the delivery cyl

inder.

AP02_980_1411EN 2

SBU software switch (SBU = switching between rod side and

piston side feed)

Using the rotary push−buttonF4, you can make use of the SBU soft

ware switch to switch the type of drive for the pump control system
between rod side or piston side pressurization.

356 AP02_980_1411EN
 Generaltechnicaldescription

Centralized lubrication system

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

Technical data Rated voltage (V DC) 12 / 24

Operating voltage (V DC) 9 to 30

Max. power consumption

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

Max. power consumption

(A) 3
for the engine at 24 V

Lamp current (A) 2

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

secure against polarity

Supply voltage inlets
reversal

secure against polarity

Supply voltage outlets reversal/short
circuit
protected

Degree of protection fitted

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

BP23_103_1208EN 357
 Generaltechnicaldescription

Programming Various settings are programmed into the centralized lubrication

system in the works. These settings regulate the lubrication intervals
and the lubrication time. Have the default settings modified by the
After Sales Department if either the lubrication intervals or the lu

brication times do not meet your needs. The following settings are
stored:

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

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

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

358 BP23_103_1208EN
 Generaltechnicaldescription

“Pump flow meter” In this menu, you can read off delivery rates in order to record job
menu volumes on the construction site, service intervals or the total deliv

ery rate, for instance. In this menu, the function buttons have the fol

lowing functions:
− F1 = Engine diagnosis" menu
− F2 = Fault memory" menu
− F4 = adjust settings

1 4 7

2 5 7

3 6 8

9 10

11 12

AP02_981_1411EN 1

No. 0 Display Function/meaning

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

AP02_981_1411EN 359
 Generaltechnicaldescription

1 4 7

2 5 7

3 6 8

9 10

11 12

AP02_981_1411EN 2

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

360 AP02_981_1411EN
 Generaltechnicaldescription

Method of operation of the pump flow meter

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

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

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

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

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

BP22_957_1104EN 361
 Generaltechnicaldescription

Setpoint value for the You can specify a value for the output at which the concrete pump
output should switch off. The accuracy of the volumes indicated is depen

dent on the current fill level of the delivery cylinders. The more
accurately you enter the fill level in percent, the more accurate
thedisplay.

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

" Then press F4 to activate the setpoint value.

å The first digit of the setpoint value flashes.

" Now turn F4 to change the first digit.

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

å The second digit of the setpoint value flashes.

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

Note
If you change the setpoint value, the actual value and the remaining
value will be reset to
0".

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

Note
As soon as the setpoint value is reached, the actual value and the
remaining value are reset to
0".

362 BP22_957_1104EN
 Generaltechnicaldescription

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

" Then press F4 to activate the value.

å The arrow flashes.

" Now turn F4 to reset the value to zero.

" Press F4 to store the changed setting.

å The arrow is displayed in inverse video again.

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

BP22_957_1104EN 363
 Generaltechnicaldescription

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

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

Amount of concrete in the truck mixer

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

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

Calculation Amount of concrete in the truck mixer 8000dm3

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

Volume of one delivery cylinder

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

å Fill level 85%

" Turn F4 to select the fill level.

å The arrow is displayed in inverse video.

" Then press F4 to activate the fill level.

å The arrow flashes.

" Now turn F4 to change the fill level.

" Press F4 to store the changed setting.

å The arrow is displayed in inverse video again.

364 BP22_957_1104EN
 Generaltechnicaldescription

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

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

1 2

AP02_982_1501EN 1

Pos.0 Display Function/meaning

1 Operating hours, digital The engine operating hours are displayed numerically.
2 Engine speed, analogue The current engine speed is displayed graphically.
Possible faults in the electronic engine governor (EMR)
3 Fault messages
are displayed.
→

AP02_982_1501EN 365
 Generaltechnicaldescription

1 2

AP02_982_1501EN 2

Continued
Pos. Display Function/meaning
DEF container fill level, ana

4 The fill level of the DEF container is shown graphically.
logue
Cooling water temperature, The cooling water temperature is displayed in
digital numbers.
5
Cooling water temperature, The cooling water temperature is displayed graphi

analogue cally.
Engine oil pressure, digital The engine oil pressure is displayed in numbers.
6 Engine oil pressure, ana

The engine oil pressure is displayed graphically.
logue
Batteryvoltage/ bat

The batteryvoltage/ batterypower are displayed in
7 terypower, digital and ana

numbers and illustrated graphically.
logue
Fuel consumption, digital The current fuel consumption is displayed in numbers.
8 The current fill level of the fuel tank is shown graphi

Fuel gauge, analogue
cally.

366 AP02_982_1501EN
 Generaltechnicaldescription

Special features of the “Engine diagnosis” menu

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

ure Mode Identifier).

AP02_982_1501EN 367
 Generaltechnicaldescription

Symbols for the “Engine diagnosis” menu

Caution
Be aware that engine damage can be caused if you operate a diesel
engine with hidden faults in the engine governor.
In emergency operation, you can recover and evacuate the ma
chine, but you cannot prevent engine damage. You operate the ma
chine at your own risk.

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

The following symbols are warnings from the electronic engine gov
ernor. A warning is signalled by a fault indicator in the display and an
acoustic warning (ifahorn is available).
If there is a fault, it may lead to the pumping operations being
stopped. In order to continue pumping, you must rectify the fault or
activate an emergency operation.
In order to activate emergency operation, select the appropriate
function or symbol and then switch this function off. The symbol is
displayed with a line through it.

Engine status
Symbol lights up red if there is a fault in the diesel engine (see the
documentation from the engine manufacturer).

Fill level warning symbol for the DEF container (orange)

The symbol lights up orange if the container content is between <5%
and >2.5%. The relevant message text also appears in the EGD.
Power reduction level 1 is being activated.

368 AP02_983_1501EN
 Generaltechnicaldescription

Fuel filter (optional)

Symbol lights up red if a fault occurs in the fuel filter or the fuel filter
is dirty.

Coolant level (optional)

Symbol lights up red if a fault occurs in the coolant reservoir or the
engine coolant level is too low.

Tank reserve (optional)

Symbol lights up yellow if the tank content has fallen to less than
15%.

Battery charging control

Symbol lights up red if the battery is not charged.

Engine oil pressure (optional)

Symbol lights up red if the engine oil pressure is too low.
If the signal for the engine oil pressure is interrupted for longer than a
few seconds, the concrete pump is switched off.

Engine oil temperature (optional)

Symbol lights up red if the engine oil temperature is higher than
90°C.
If the signal for the engine oil temperature is interrupted for longer
than a few seconds, the concrete pump is switchedoff.

AP02_983_1501EN 369
 Generaltechnicaldescription

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

1 2 3 4

BP22_965_1105EN 1

No. 0 Display Function / meaning

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

370 BP22_965_1105EN
 Generaltechnicaldescription

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

BP22_947_1104EN 1

No. 0 Display Function / meaning

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

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

BP22_947_1104EN 371
 Generaltechnicaldescription

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

1 2
BP22_946_1104EN 1

No. 0 Display Function / meaning

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

372 BP22_946_1104EN
 Generaltechnicaldescription

3.6.3 Ergonic Output Ergonic Output Control(EOC) is electronically controlled delivery

Control rate 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 EOCfunction is switched off, the maximum engine speed

specified at the works is activated.

“Pump settings”
1
menu

AP02_984_1411EN 1

No. 0 Display Function/meaning

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

AP02_984_1411EN 373
 Generaltechnicaldescription

Special features of Ergonic Output Control

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

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

Starting the engine After starting the engine, the engine speed stays at idling speed.

Hydraulic fluid tem If the hydraulic fluid temperature is less than 25°C, the delivery rate
perature is reduced to a maximum of 50% in EOCoperation. If the hydraulic
fluid temperature exceeds 25°C, the delivery rate is changed to the
value which has been set at the potentiometer on the cable remote
control.

374 AP02_984_1411EN
 Generaltechnicaldescription

Pump On As soon as you switch on the concrete pump, the engine speed is
increased to a level appropriate for the delivery rate set on the out

put regulation rotary controller, but to no less than 1600rpm.

Delivery rate Engine speed

0% 850rpm (after 5seconds)
0−80% 1600rpm
>80 % 1600rpm−maximum engine speed

If the delivery rate is set to more than 80 %, the engine speed is in

creased 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 80 %, the engine speed is held
at 1600rpm. The actuating pressure for the hydraulic pump is then
modified automatically.

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

AP02_984_1411EN 375
 Generaltechnicaldescription

Pump Off The engine speed is reduced to idling speed after 5seconds (works
setting), when you
− reduce the delivery rate to 0 %.
− switch off the concrete pump.
Should you switch the concrete pump back on inside this 5second
delay, the engine speed is maintained.

Water pump and other You must increase the engine speed manually in order to operate the
auxiliary units water pump or the other auxiliary units. As soon as you switch off the
water pump, the engine speed is reduced to 850rpm after 10sec

onds (works setting). If you should switch the water pump back on
within these 10seconds, the engine speed is maintained.

Adjusting the engine If you change the engine speed manually using the cable remote
speed manually control while the concrete pump is switched on, this manually set en

gine speed is retained until you:
− adjust the delivery rate at the rotary controller again.
− switch off the ignition.

376 AP02_984_1411EN
 Generaltechnicaldescription

Menu–independent If a serious change to the operating status of the machine occurs

warnings that may lead to a major fault, this warning will appear on the screen
regardless of the current system menu.

Danger of fire
Risk of fire due to inadequate clearance from a stationary concrete
pump during the DPF regeneration procedure.
During the DPF regeneration procedure in particular, very high ex
haust gas and surface temperatures occur near a stationary con
crete pump.
Only activate the DPF regeneration procedure outdoors.
Look for a setup site that has sufficient clearance to other machines,
combustible materials and flammable liquids.
Use your personal protective equipment.

Note
The warning strategy of the SCR system complies with the relevant
national codes of practice.
The following faults that are relevant to emissions are therefore dis
played:
 Fill level of the DEF container
 DEF quality and exhaust gas treatment
 DPF regeneration
 Manipulation
(See section
Menu−independent warnings").

Note
The warning symbols and message texts described in this section
are shown in every menu. For as long as a warning is displayed, an
acoustic warning signal sounds at the stationary concrete pump. The
warning will be displayed until the fault is rectified.

AP02_975_1704EN 377
 Generaltechnicaldescription

Warning triangle, yellow

Symbol lights up yellow in the following cases:

− Once the tank content is between <10% and >5%,

− If a DPF regeneration is required or if regeneration is running
− If DEF quality and exhaust gas treatment are poor.

Warning triangle, orange

Symbol lights up orange in the following cases:

− Once the tank content is between <5% and >2,5%,

− If DPF regeneration is required and shows escalation stage1,
− If DEF quality and exhaust gas treatment are inadequate.
Power reduction stage 1: The engine torque is reduced by 25% (see
the engine manufacturer’s documentation).

Warning triangle, red

Symbol lights up red in the following cases:

− Once the tank content is between <2,5% and 0%,

− If DPF filter maintenance is required and shows escalation stage2,
− If DEF quality and exhaust gas treatment are insufficient.
Power reduction stage 2: The engine torque is reduced by 50% and
the rated speed by 60% (see engine manufacturer’s documentation).

378 AP02_975_1704EN
 Generaltechnicaldescription

Warning symbol: DPF regeneration (yellow)

Symbol lights up yellow if DPF regeneration is required.

Warning symbol: DPF regeneration (orange)

Symbol lights up orange if DPF regeneration is required and shows
the escalation stage 1. Power reduction stage 1 is activated.

Warning symbol: DPF regeneration (red)

Symbol lights up red if DPF filter maintenance is required and indi

cates escalation stage2. Power reduction level2 is activated (SER

DIA service tool is required, see also the documentation from the en

gine manufacturer).

Warning symbol: DPF regeneration running (yellow)

Symbol lights up yellow if DPF regeneration is running. The thermom

eter symbol warns of extremely high exhaust gas temperatures
(>600°C) that can arise during the stationary regeneration pro

cedure.

Warning symbol: DPF regeneration complete (green)

Symbol lights up green if DPF regeneration is complete.

Note
Once the
DPF regeneration warning symbol" lights up yellow, you
must manually start the DPF regeneration procedure/stationary re
generation.

AP02_975_1704EN 379
 Generaltechnicaldescription

1 2 3 4

5
AP02_975_1704EN 1

Example warning illustration: DPF regeneration required

Pos.0 Display Function/meaning

Warning levels (yellow, orange and red) depend on the
status of regeneration/stationary regeneration
1 Warning triangle
If the warning level is orange or red, the power to the
engine is reduced
Warning levels (green, yellow, orange and red) de

2 Warning symbol pend on the status of regeneration/stationary regener

ation = pumping operations stopped
The time remaining for DPF regeneration in [minutes]
3 Countdown display, digital
is displayed in numbers
The following message texts are displayed depending
on the warning level (green, yellow, orange and red)
and activation status of the DPF regeneration:
Green: DPF regeneration complete"
Yellow: DPF regeneration required" or DPF regener

4 Message text
ation running"
Orange: DPF regeneration required"
Red: DPF filter maintenance required" (SERDIA ser

vice tool required, see the engine manufacturer’s
documentation)
The following message texts are displayed depending
5 Message text on the warning level:
Orange or red: Power reduction"

380 AP02_975_1704EN
 Generaltechnicaldescription

Fill level warning symbol for the DEF container (green)

Symbol lights up dark green if the fill level in the DEF container is
>15%, and light green if the container content is between <15% and
>10%.

Fill level warning symbol for the DEF container (yellow)

This symbol lights up yellow if the container content is between
<10% and >5%.

Fill level warning symbol for the DEF container (orange)

This symbol lights up orange if the container content is between
<5% and >2.5%. Power reduction stage 1 is activated.

Fill level warning symbol for the DEF container (red)

This symbol lights up red if the container content is between <2.5%
and 0%. Power reduction stage 2 is activated.

AP02_975_1704EN 381
 Generaltechnicaldescription

1 2 3

4
AP02_975_1704EN 2

Example warning illustration: DEF fill level low, top up DEF

Pos.0 Display Function/meaning

Warning levels (yellow, orange and red) depend on the
liquid level of the DEF container
1 Warning triangle
If the warning level is orange or red, the power to the
engine is reduced
Warning levels (dark green, light green, yellow, orange
2 Warning symbol and red), depending on the liquid level of the DEF
container
Depending on the warning level (yellow, orange and
red), the following message texts are displayed:
3 Message text
Yellow, orange and red: DEF fill level low", Top up
DEF"
The following message texts are displayed depending
4 Message text on the warning level:
Orange or red: Power reduction"

382 AP02_975_1704EN
 Generaltechnicaldescription

Caution
Damage to the SCR system if the diesel exhaust fluid (DEF) quality
does not comply with the specifications of ISO22241.
If the DEF quality deteriorates, the complete engine system cannot
comply with the permitted exhaust gas values.
Do not dilute the DEF, as this will cause damage to the SCR system.
Do not fill the DEF container with diesel fuel, as this will cause dam
age to the SCR catalytic converter.
Use only the specified DEF−quality products.
Observe the
DEF quality warning symbols" in the EGD; these are
displayed when sub−standard DEF quality or a manipulated or de
fective component has been detected.

Warning symbol for DEF quality and exhaust gas treatment (yel-
low)
Symbol lights up yellow if the DEF quality and exhaust gas treatment
are poor.

Warning symbol for DEF quality and exhaust gas treatment

(orange)
Symbol lights up orange if the DEF quality and exhaust gas treat

ment are inadequate. Power reduction stage 1 is activated.

Warning symbol for DEF quality and exhaust gas treatment (red)
Symbol lights up red if the DEF quality and exhaust gas treatment
are insufficient. Power reduction stage 2 is activated.

AP02_975_1704EN 383
 Generaltechnicaldescription

1 2 3

4
AP02_975_1704EN 3

Example warning illustration: DEF quality inadequate

Pos.0 Display Function/meaning

Warning levels (yellow, orange and red) depend on the
DEF quality and exhaust gas treatment.
1 Warning triangle
If the warning level is orange or red, the power to the
engine is reduced
Warning levels depending on the DEF quality and ex

2 Warning symbol haust gas treatment or in the event of DEF manipula

tion (yellow, orange and red)
Depending on the warning level (yellow, orange and
red), the following message texts are displayed:
3 Message text
Yellow, orange and red: DEF quality inadequate" or
DEF manipulation detected"
The following message texts are displayed depending
4 Message text on the warning level:
Orange or red: Power reduction"

384 AP02_975_1704EN
 Generaltechnicaldescription

Warning symbol for engine oil change required (yellow)

Symbol lights up yellow if the engine oil needs to be changed.

Note
The engine oil must be changed every 500 hours or after the DPF
has been regenerated several times, and if the warning symbol
En
gine oil change required" is displayed.

1 2

AP02_975_1704EN 4

Example warning illustration: Engine oil change required

Pos.0 Display Function/meaning

1 Warning symbol Engine oil change required
2 Message text Yellow: Engine oil change required"

AP02_975_1704EN 385
 Generaltechnicaldescription

1 2

AP02_975_1704EN 5

Example warning illustration: Fill level of the DEF container

Pos.0 Display Function/meaning

Warning levels (dark green, light green, yellow, orange
1 Warning symbol and red), depending on the liquid level of the DEF
container
The fill level of the DEF container is shown in numbers
2 Display, digital
as a percentage.

386 AP02_975_1704EN
 Generaltechnicaldescription

3.6.4 Cable remote control The most important control functions for the pump are gathered to

gether on the remote control unit, so that you can control the oper

ation of the pump from here.

1 2 3 4 5 6 7

AP02_625_1301EN 1

Operating/
No. 0 Meaning/Function Comments
control element
1 Momentary
contact EMERGENCY STOP
switch
2 Rotary controller Increase − Reduce output
3 Toggle switch Engine On − Off
4 Toggle switch Pump On − 0 − Reverse pumping
5 Toggle switch Deactivate EMERGENCY STOP / change−
over
6 Toggle switch Increase − Reduce engine speed
7 Toggle switch Ergonic Output Control (EOC) On−Off

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

To release the EMERGENCY STOP condition again, you must unlock

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

You must operate the
Deactivate EMERGENCY STOP" toggle switch

on the control cabinet to make the pump operational once more.

AP02_625_1301EN 387
 Generaltechnicaldescription

Special features of the cable remote control

Starting up the pump If you have pressed the EMERGENCY STOP button, the EMERG

after EMERGENCY ENCY STOP activated" symbol flashes on the Ergonic Graphic Dis

STOP play. You may only start the pump up again as described below:
− Unlock the EMERGENCY STOP button by turning it,
− Operate the Deactivate EMERGENCY STOP" toggle switch,
å The EMERGENCY STOP activated" symbol does not flash
on the Ergonic Graphic Display.
− Switch the pump on.

388 AP02_625_1301EN
 Generaltechnicaldescription

3.6.5 Operating panel You can switch functions on and off using the operating elements in
the operating panel.
Some of the control and operating elements illustrated below may
not be present on your machine. The hole will be filled with a blank

ing plug if a control or operating element is omitted.

1 2 3 4

7 6 5

AP02_949_1508EN 1

Operating-/
No. 0 Meaning/function
control element
1 Toggle switch Acknowledging the agitator safety cutout
2 Toggle switch Pump Off
AgitatorOn− agitation direction away from the
delivery cylinder
3 Toggle switch Agitator Off
AgitatorOn− agitation direction towards the de

livery cylinder
4 Toggle switch Open gate valve− 0− close gate valve
5 Toggle switch Vibrator On−Off
6 Toggle switch Flushing water pump − agitator − set
up foot
7 EMERGENCY STOP button The machine is switched off.

AP02_949_1508EN 389
 Generaltechnicaldescription

Special features of the operating panel

Starting up the pump If you have pressed the EMERGENCY STOP button, you may only
after EMERGENCY start the pump up again as described below:
STOP − Unlock the EMERGENCY STOP button by turning it.
− Operate the Deactivate EMERGENCY STOP" toggle switch on the
remote control.
− Switch the pump off and then back on again using the
PumpOn−0" toggle switch on the remote control.

Water pumps The valves for the agitator control block are actuated so that the
water pump, agitator and set
up foot function do not operate simulta

neously.

390 AP02_949_1508EN
 Generaltechnicaldescription

3.6.6 EMERGENCY STOP EMERGENCY STOP buttons are fitted to the following machine com

button ponents:
− the cable remote control
− on the right−hand side of the machine in the operating panel.

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

AP21_090_1701EN 1

EMERGENCY STOP button

Note
In order to trigger an EMERGENCY STOP on the machine, you must
press one of the EMERGENCY STOP buttons.

To release the EMERGENCY STOP condition again, you must unlock

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

To make the pump start up again, you must press the
Deactivate
EMERGENCY STOP" toggle switch.

AP21_090_1701EN 391
 Generaltechnicaldescription

The following actions are triggered when you press one of the
EMERGENCY STOP buttons:
− The EMERGENCY STOP symbol is shown in red on the control
cabinet,
− The variable main pump swings back, and the delivery pistons
stop,
− The change
over valve is de−energized.

Note
If the machine has an electrical agitator safety cutout, the accumula
tor dump valve is opened and the accumulator emptied when the
EMERGENCY STOP button is pressed. The agitator will stop.

To start up the agitator again, you must actuate the
Acknowledge

agitator/agitator safety cutout" toggle switch on the control cabinet.

392 AP21_090_1701EN
 Generaltechnicaldescription

3.6.7 Agitator safety cutout The agitator safety cutout consists of a transponder and an evalu

(RSA) ation device with reading head. As soon as you open the grille, the
radio link between the transponder and reading head is broken.
Thiscauses the agitator to halt and the pressure to be dumped from
the accumulator, i.e. the transfer tube will no longer be able to switch
over. In addition, the delivery pistons return to the end position and
the concrete pump halts. To restart the concrete pump, you must first
switch it off and then back on again. In order that the agitator starts
turning again and the accumulator refills, you must acknowledge the
agitator safety cutout in the operating panel.

1 2

3
4

AP02_951_1402EN 1

Pos.0 Designation
1 Transponder (on the grille)
2 Acknowledge agitator safety cutout in the operating panel
3 LED, green and red
4 Reading head (on the hopper − example illustration)

AP02_951_1402EN 393
 Generaltechnicaldescription

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

Therefore, always check that the agitator safety cutout is working

properly before using the pump.

The LEDs on the evaluation device indicate the following:

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

394 AP02_951_1402EN
 Generaltechnicaldescription

3.6.8 Magnetic switches The distributor casing for the magnetic switches is located beneath
distributor casing the control cabinet.

1 3

2 5 4
AP02_614_0706EN 1

Belongs
No. 0 Control element Meaning/Function
with no.:
1 Yellow LED Magnetic switch (rod side), drive cylinder II 1
2 Yellow LED Magnetic switch (rod side), drive cylinder I 2
3 Yellow LED Magnetic switch (piston side), drive cylinder II 3
4 Yellow LED Magnetic switch (piston side), drive cylinder I 4
5 Green LED In service lamp 5

LEDs There are two magnetic switches on each drive cylinder of the core
pump, one at the front and one at the rear. These switches trigger
the switchover procedure when the hydraulic pistons approach the
magnetic switches. The yellow LEDs for the two magnetic switches
that have just been triggered light up on the distributor casing at the
same time.

AP02_614_0706EN 395
 Generaltechnicaldescription

Significance of
LED for magnetic switch Magnetic switch status
theLEDs
lights up briefly on switchover Magnetic switch is OK

does not light up on switchover Magnetic switch, connector or

lead are defective, replace at
the earliest opportunity

lights up continuously Magnetic switch, connector

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

In service lamp Distributor casing status

lights up continuously The distributor casing is ready

for operation.

does not light up The Putzmeister operating

system is not supplied with
avoltage.

Note
Additional LEDs are located on the magnetic switch connector (see
page 397). These LEDs indicate whether it is the magnetic switch
or the connector and lead that is defective.

Redundant system One magnetic switch is sufficient to trigger the switchover pro

cedure. The second magnetic switch is fitted as a backup in case
one of the two magnetic switches should fail (redundant system).
You may use one of the magnetic switches from the other side as a
replacement if both the switches on one side (rod side or piston
side) fail during a job.

396 AP02_614_0706EN
 Generaltechnicaldescription

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

1 2

20500406

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

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

BP02_428_9707EN 397
 Generaltechnicaldescription

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

does not light up on switchover Magnetic switch is defective,

replace at earliest opportunity

lights up continuously Magnetic switch is defective,

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

Green LED Connector and lead status

lights up A voltage is being applied to the

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

does not light up No voltage is being applied to

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

398 BP02_428_9707EN
 Generaltechnicaldescription

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

The hydraulic control devices may include the following components,

depending on the equipment on your machine.
− agitator lever
− water pump lever
− compressor lever
− output controller
− accumulator dump cock
− transfer tube damping cock

Note
Further control devices and components are described in the

Electrical control devices" (from page 322) and
Other
components" (from page 3105) sections.

AP02_058_9801EN 399
 Generaltechnicaldescription

3.7.1 Water pump lever The water pump lever is used to switch the water pump on or off.

AP02_245_1402EN 1

No.0 Designation
1 Water pump off
2 Water pump on

3100 AP02_245_1402EN
 Generaltechnicaldescription

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

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

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

the pump control system, this is located behind guard.

4
AP21_089_1701EN 1

Pos.0 Designation
1 Accumulator
2 Pump control system
3 Transfer tube damping cock
4 Accumulator dump valve

AP21_089_1701EN 3101
 Generaltechnicaldescription

3.7.3 Agitator emergency If the control panel has failed, you can use different directions of
operation rotation to manually operate the agitator from the hydraulic control
block illustrated below.

AP21_054_1609EN 1

Pos. 0 Designation
1 Agitator emergency operation

3102 AP21_054_1609EN
 Generaltechnicaldescription

3.7.4 Pressure gauge The hydraulic pressure of the hydraulic pump is shown on the
pressure gauge.

AP02_063_0308EN 1

3.7.5 Filter condition The condition of the suction filter can be seen on the vacuum meter,
that of the pressure filter can be seen directly on the filter housing.

Suction filter

AP02_063_0308EN 2

Vacuum meter

Pressure filter

AP02_063_0308EN 3

Filter housing with indicator

AP02_063_0308EN 3103
 Generaltechnicaldescription

3.7.6 Automatic–Piston– The APP system makes it easier to fit and remove the delivery pis

Pull (APP) tons.

A ball valve is fitted in the stroke correction line of each drive cylin

der. The two ball valves are open and secured by guide washers.
The ball valves may only be closed when the delivery pistons are
being replaced.

2
3
1

No.0 Designation
1 Drive cylinder II
2 Ball valve for drive cylinder II
3 Ball valve for drive cylinder I
4 Drive cylinder I
5 Opened and secured ball valve

Caution
The ball valves must be opened and secured by the guide washers
when the machine is being operated.

If the ball valves were closed, the delivery pistons would strike
against the stop plates in the water box. This might result in the deliv
ery pistons breaking off their piston rods.

3104 BP22_899_1008EN
 Generaltechnicaldescription

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

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

The following components may be described here, depending on

the equipment on your machine.
− manual throttle lever for the engine
− flushing water pump
− high−pressure water pump
− compressor
− vibrator
− hydraulic fluid radiator

Note
Further control devices and components are described in the
Hy
draulic control devices" (from page 399) and
Electrical control
devices" (from page 322) sections.

AP02_059_9801EN 3105
 Generaltechnicaldescription

3.8.1 Hydraulic fluid Some of the hydraulic fluid in the machine first flows through a radi

radiator ator before it returns to the reservoir. The hydraulic fluid radiator fan
can be switched on and off manually on the control cabinet.

20204201

No. 0 Description
1 Control cabinet symbol for the hydraulic fluid radiator
2 Hydraulic fluid return circuit
3 Fan
4 Hydraulic fluid supply circuit

3106 AP02_301_0206EN
 Generaltechnicaldescription

3.8.2 Flushing water pump Depending on the machine specification, it may be equipped with
either a Hypro WP 50 or a CRK 4−160.

Flushing water pump The flushing water pump Hypro WP 50 generates a water pressure of
Hypro WP 50 20bar at a water delivery rate of 50litres per minute maximum.

1 2 3

11201701

No. 0 Designation
1 High−pressure water hose
2 Water pressure gauge
3 Pressure limiting valve
4 Claw coupling for high−pressure water hose
5 Flushing water pump
6 Claw coupling for the water supply

AP02_787_1008EN 3107
 Generaltechnicaldescription

Flushing water pump The flushing water pump CRK 4−160 generates a maximum water
CRK 4–160 pressure of 25bar and a maximum water delivery rate of 160litres
per minute.

1
5

4
2

AP02_787_1008EN 1

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

3108 AP02_787_1008EN
 Generaltechnicaldescription

3.8.3 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; the connecting
plug must be plugged into the appropriate socket on the control
cabinet for this to work.

1
3

4
31201000

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

The vibrator is switched on and off from the control cabinet, or

optionally through the remote control.

AP02_014_9612EN 3109
 Generaltechnicaldescription

3.8.4 Exhaust after treat- This section provides a description of the exhaust after treatment
ment system system.
The engine and its exhaust after treatment system are coordinated
with one another and form a complete engine system. The complete
engine system meets the permitted exhaust gas emission levels and
is certified accordingly by the relevant authorities.

Danger
Risk of burning when touching components that conduct exhaust
gases.
In particular during the diesel particle filter (DPF) regeneration pro
cedure, extremely high exhaust gas and surface temperatures arise
at the exhaust after treatment system.
Maintain a sufficient distance from the exhaust after treatment sys
tem. Use your personal protective equipment.

Caution
It is not permissible to operate the engine using a different exhaust
after treatment system.
It is not permissible to carry out unauthorized changes to the exhaust
after treatment system. The engine manufacturer is not liable for any
damage caused as a result.
Only operate the engine if the exhaust after treatment system is
working correctly; otherwise the permitted exhaust gas emission le
vels may not be met.
Observe the applicable national exhaust gas emission regulations to
ensure compliance with exhaust gas emission levels.

Caution
Failure to comply with the requirements and recommendations for
functional fluids of the engine manufacturer may result in damage to
the complete engine system.
Observe the requirements and recommendations for operating ma
terials (lubricating fluid, permitted fuels, coolant and diesel exhaust
fluid) in the engine manufacturer’s documentation.

3110 AP02_987_1702EN
 Generaltechnicaldescription

Note
Refer to the engine manufacturer’s documentation for details about
how the exhaust after treatment system works.
Abbreviations used:
EAT = Exhaust After Treatment (after treatment of exhaust gas)
DEF = Diesel Exhaust Fluid (urea solution used in exhaust gas treat
ment, e.g.
AdBlue")
DPF = Diesel Particle Filter
DOC = Diesel Oxidation Catalyst
SCR = Selective Catalytic Reduction
NOx = Nitrogen Oxide

AP02_987_1702EN 3111
 Generaltechnicaldescription

Selective Catalytic Reduction (SCR)

11

2 3 3
10

6 5 4
AP02_987_1702EN 1

Example illustration: SCR system

Pos.0 Component
1 Engine control unit
2 Solenoid−operated valve
3 Line heated with coolant (to preheat the DEF container)
4 DEF container
5 DEF delivery pump
6 DEF line
7 Line cooled with coolant (to cool the metering unit)
8 SCR catalytic converter
9 Metering unit
10 Exhaust gas temperature sensor
11 NOx sensor

3112 AP02_987_1702EN
 Generaltechnicaldescription

The SCR system continuously reduces the NOx emissions produced

by the engine as described below:
The DEF delivery pump supplies the diesel exhaust fluid (DEF) that
is injected into the exhaust system by the metering unit upstream of
the SCR catalytic converter.
The DEF injected into the exhaust system reacts with the NOx
emissions present in the exhaust gas in the catalytic converter of the
SCR system. This reduces the NOx emissions to nitrogen (N2) and
water (H2O).
The engine control unit controls the DEF injection volume.

Caution
Leaking DEF lines may cause damage to electrical and electronic
components in the engine compartment.
Leaking diesel exhaust fluid (DEF) can cause corrosion damage and
operating faults if it comes into contact with cabling, control units
and similar electronic components (e.g. short circuiting, malfunctions
and the destruction of electronic components).
Check the DEF lines and line connections for leak tightness. Seal
any leakage points.
Electronic components (e.g. sensors) that can come into contact
with DEF must be connected using lines that are sealed all the way
along.

AP02_987_1702EN 3113
 Generaltechnicaldescription

Diesel Oxidisation Catalyst/Diesel Particle Filter (DOC/DPF module)

1
2
3
4

AP02_987_1702EN 2

Example illustration: Diesel particle filter (DPF)

Pos.0 Component
1 DOC  diesel oxidisation catalyst
2 Exhaust gas temperature sensor
3 Pressure differential sensor
4 DPF  diesel particle filter

3114 AP02_987_1702EN
 Generaltechnicaldescription

The diesel oxidisation catalyst (DOC) oxidises the carbon monoxide

(CO) and unburned hydrocarbons (HC) present in the exhaust gas.
Within a temperature range of 200°C to 450°C, nitrogen monoxide
(NO) is converted into (NO2) through oxidation.

The diesel particle filter (DPF) with passive regeneration capabilities

separates the soot created during the diesel fuel combustion pro

cess. The DPF must be regenerated as soon as it becomes increas

ingly loaded with soot.
The passive diesel particle filter is regenerated by burning the soot
particles using the nitrogen oxide (NOx) contained in the exhaust
gas.
The continuous DPF regeneration procedure lasts approx. 40 min

utes and takes place at exhaust gas temperatures of approx. 580°C
on the DOC/DPF module.
The engine control unit monitors the loading of the diesel particle
filter.

AP02_987_1702EN 3115
 Generaltechnicaldescription

DPF regeneration strategy

Note
Refer to the engine manufacturer’s documentation for details about
the regeneration strategy.

Danger of fire
Risk of fire due to an inadequate clearance from a stationary con
crete pump during the regeneration procedure.
During the regeneration procedure in particular, very high exhaust
gas and surface temperatures occur near a stationary concrete
pump (approx. 600°C).
Activate the regeneration procedure out in the open air only.
Select a set−up site that has sufficient clearance from other ma
chines, combustible materials and flammable liquids.
Use your personal protective equipment.

Danger
Risk of burning when touching components that conduct exhaust
gases.
During the stationary regeneration in particular, very high exhaust
gas and surface temperatures occur at the exhaust after treatment
system (approx. 600°C).
You are not permitted to use the machine during stationary regener
ation.
Maintain a sufficient distance from the exhaust after treatment sys
tem. Use your personal protective equipment.

3116 AP02_987_1702EN
 Generaltechnicaldescription

Regeneration strat- Description/DPF soot load Ergonic Buzzer Power reduction

egy/colour code Graphic
Display
Normal operation

Regeneration not required.

Off Off None
Dark green DPF soot load < 62%

Passive regener- Required

ation 1 = Passive regeneration takes
Heat mode 1 place continuously during en

en
gine operation. Off Off None
Actions inside the engine are
Green
enabled.
DPF soot load > 62%
Passive regener- Required
ation 2 = Passive regeneration takes
Heat mode 2 place continuously during en

en
gine operation. Off Off None
Actions inside the engine are
Green
enabled.
DPF soot load > 78%
Active regener- Regeneration required.
ation = Operation can continue but re

Standstill generation is urgently required.
Active regeneration must be in
On Off None
itiated manually by the machine
Yellow
operator.
DPF soot load > 100%

AP02_987_1702EN 3117
 Generaltechnicaldescription

Regeneration strat- Description/DPF soot load Ergonic Buzzer Power reduction

egy/colour code Graphic
Display
Active regener- Regeneration required.
ation Operation can continue but re

Warning level generation is urgently required.
Active regeneration must be in
On On 25%
itiated manually by the machine
Orange
operator.
DPF soot load > 109%
Active regener-
ation Regeneration using Service
Switch–off step Tool required. 50% of max. torque
Regeneration
R ti iis iinitiated by
iti t d b and
d
On On
DEUTZ After Sales department. speed limit 60% of
Red the nominal speed
DPF soot load > 125%

Filter change Filter change required.

50% off max. ttorque
Filter is changed by DEUTZ
and
After Sales department. On On
Dark red speed limit 60% of
Regeneration not permissible.
the nominal speed
DPF soot load > 156%

3118 AP02_987_1702EN
 Startingup

4 Starting up

In this chapter you will learn the steps necessary when starting up
your machine for the first time, and how to prepare your machine for
use if left idle for a prolonged period.

Information is available on how to check your machine and how to

carry out a test run with visual and function checks.

Note
The operating personnel must be instructed in the use of the
machine the first time it is started up.

AP13_015_0303EN 4I
 Startingup

4II AP13_015_0303EN
 Startingup

4.1 Visual checks You must check the condition of the machine and carry out a test run
with function checks each time before you start to use it. If you notice
a defect, you must have this rectified immediately, if necessary by
qualified personnel.

Note
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.

4.1.1 Hydraulic system The fundamental prerequisite for problem−free use is a fully func

tional hydraulic system.

" Check that all hydraulic lines, threaded unions and cylinders
are tight.
Maintenance card: Hoses

Caution
Operation is not possible if the hydraulic cylinders are leaking,
please consult Putzmeister After Sales Department.

AP13_022_0303EN 41
 Startingup

4.1.2 Functional fluids Making ready for operation also includes topping up the functional
fluids.

MAX

MIN

MAX

MIN

10000702

Water, fluid 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.

Note
The machine must be level when you check the functional fluids. The
water box must be full during operation, even if there is a risk of
freezing.

" Check all water, fluid and fuel levels and top these up as
necessary.

42 AP13_022_0303EN
 Startingup

4.1.3 Condensate water Water of condensation can form in the hydraulic fluid reservoir and
settle at the deepest point if the machine is shut down for some time.

AP13_022_0303EN 1

" Place a suitable container under the drain cock to catch the
escaping condensate water.

" Open the drain cock. Close the cock again as soon as fluid
runs out.

4.1.4 Lubrication points

" Check that all lubrication lines are tight and free from fracture.

" Check that all lubrication points have been lubricated.

4.1.5 Hydraulic fluid

radiator
" Check the hydraulic fluid radiator and, if necessary, carefully
clean the radiator panel.

AP13_022_0303EN 43
 Startingup

4.1.6 Water box The water box is fitted between the drive cylinders and delivery
cylinders. To be able to better check the water level and the condi

tion of the water, you have to open the water box, i.e. remove the
perforated plate.

Danger of crushing
You could suffer severe injuries from crushing or the shearing action
of components.

Never reach into the open water box to check it.

" Open the water box.

" Check the water level.

å The piston rods must be completely covered.

" Check the water condition.

å The drive cylinders are leaking if there is a clearly visible
escape of fluid, particularly at the piston rods.
å At least one of the delivery pistons is worn if the amount of
sludge in the water box is unusually high.

" Check the securing wires on the bolts on the spacer flange.
å Check the tightening torques on the bolts if the securing
wires are damaged.

Maintenance card: Delivery piston replacement

" Close the water box again.

Note
Small quantities of fluid in the water box originate from the dry run
ning cut−out for the delivery pistons. The drive cylinders are only
leaking if there is a clearly visible escape of fluid.

44 AP13_022_0303EN
 Startingup

4.1.7 Parts in contact You should always check the parts which come into contact with
with concrete concrete before using the machine:

" Disconnect the delivery line bend at the pressure connection.

" Illuminate the transfer tube from the pressure connection using
a pocket torch and check the inner wall of the pipe and its
thrust ring for wear.

" Reconnect the delivery line bend to the pressure connection.

" Look into the hopper and check on the condition of the spec

tacle wear plate and the wear ring. The parts must be replaced
if there is clearly detectable wear (e.g. deep grooves).

10701400

Check spectacle wear plate

" Check that all safety equipment is fitted and fully functional.

Caution
The agitator grille must be closed and secured.

AP13_022_0303EN 45
 Startingup

4.2 Test run Depending on the machine’s equipment, the following sequence of
actions must be carried out for the test run:
− Open the ventilation flap (as soon as the machine is warm)
− Open the side flaps (as soon as the machine is warm)
− Switching on the machine

You must now check several functions with the machine running.

Caution
The ventilation flap must be open before you switch on the machine.

All operating elements on the control cabinet, in particular the main

switch and the EMERGENCY STOP button, must be quickly access
ible at all times during operation.

The side flap in front of the control cabinet must not be closed once
the engine has been switched on if this obscures the operating el
ements.

Caution
Damage to the engine caused by potential malfunctions in the fuel
and exhaust after treatment system.
Bleeding the fuel system is also urgently required. Start the five−min
ute test run while idling up to an operating temperature of approx. 90
°C.
Check the leak tightness of the engine, the lubricating fluid pressure
and the lubricating fluid level.
Check the exhaust after treatment system for leak tightness.
The SCR system requires a warming up and thawing phase of ap
prox. 30 minutes at ambient temperatures of below 0 °C. The heated
SCR components (e.g. DEF containers, DEF lines and DEF delivery
pump) are thawed.
Observe the requirements and recommendations in the engine
manufacturer’s documentation.

46 AP13_103_1501EN
 Startingup

4.2.1 Switching on the ma- Before switching on the machine, you must set up the machine cor

chine rectly, have the control cabinet connected to the electrical power
supply and must set up the cable remote control for use.

You can find information on this in the chapter entitled Transport,

setting up and connection".

Switching on the en- The engine can only be switched on when it is under no load, i.e.
gine there must be no consumers switched on.

1 2

3 AP13_106_1508EN 1

Example illustration

No. 0 Designation
1 Operating panel
2 Water pump
3 Output controller (potentiometer)

" Switch off all of the consumers at the operating panel(1).

" Switch off the water pump (2).

" Turn the Increase − Reduce output" potentiometer(3) on the

cable remote control to min".

AP13_106_1508EN 47
 Startingup

1 2

AP13_106_1508EN 2

Example illustration

No. 0 Designation
1 Ergonic Graphic Display (EGD):
Setting and displaying operating states
2 Locally latched toggle switch:
Localcontrol− 0− Remotecontrol
3 Ignition−starter switch: Engine On−Off

" Shift the toggle switch(2) on the control cabinet to Re

motecontrol".

" Switch the ignition on using the ignition
starter switch(3).

å The Ergonic Graphic Display(1) lights up.

48 AP13_106_1508EN
 Startingup

" Operate the Deactivate EMERGENCY STOP" toggle switch on

the cable remote control.

" Switch the diesel engine on using the ignition
starter switch(3)

on the control cabinet or using the Diesel engine On−Off"
toggle switch on the cable remote control.

" Switch the pump on at the cable remote control using the
PumpOn/Off − Reversepumping" toggle switch.

" Set the desired output using the Increase − Reduce output"
potentiometer on the cable remote control.

" Use the EGD operating elements(1) to navigate in the menu

structure and to make settings.

AP13_106_1508EN 49
 Startingup

4.3 Function checks Before using the machine on site, systematically check the functions
of the components with the machine running.

4.3.1 Pump The fundamental prerequisite for problem−free use is a fully

functional pump.

Switch over Check for an unimpeded switchover function of the delivery pistons
and the transfer tube at various engine speeds and positions of the
output controller.

Magnetic switches

AP13_026_0510EN 1

Checking the magnetic switches

Check that the drive cylinders switch over automatically once the
hydraulic pistons are close to the magnetic switches. The green
in−service lamp on the distributor casing must remain lit during
thisprocess. The yellow LEDs will light up briefly as soon as the
hydraulic piston approaches its magnetic switch. If one of the LEDs
does not light up, the associated magnetic switch is defective.

410 AP13_026_0510EN
 Startingup

Stroke length Press and hold the change−over button at low delivery piston speed.
The delivery pistons move to their end positions. Stroke correction is
automatic and is complete when both delivery pistons come to a halt
(may be seen in the water box).

Stroke time Measure the machine stroke time under no load, i.e. without
concrete.

" Set the engine to maximum speed.

" Set the maximum pumping rate.

" Start the measurement at the first switch over of the transfer
tube.
å The first single stroke is complete with the next transfer
tube switch over.

" Measure the stroke time over a period of ten single strokes.

The value measured, divided by ten, must match the data in the test
reading.

Note
Due to differences in reaction times when using the stopwatch, the
value determined may vary from the value stated by approximately 5%.
You may have to take the measurement several times and calculate
the mean of the values measured.

AP13_026_0510EN 411
 Startingup

4.3.2 EMERGENCY STOP It is only possible to intervene rapidly in the event of danger if all
buttons EMERGENCY STOP buttons on the machine and on the remote
control are functioning correctly.

Caution
The machine is no longer safe to operate if an EMERGENCY STOP
button is defective, as you will no longer be able to switch off the
machine quickly enough if danger threatens. You must therefore
check the functioning of the EMERGENCY STOP buttons each time
you start work.

EMERGENCY STOP
button

10500200

Press: lock EMERGENCY STOP

Turn: unlock EMERGENCY STOP

" Switch the pump on.

" Operate a control function (e.g. Reverse pumping On").

" Press one of the EMERGENCY STOP buttons.

å The pump must stop immediately.

" Check all EMERGENCY STOP buttons on the machine and

onthe remote control in the same way.

412 AP13_027_0904EN
 Startingup

4.3.3 Function check of the This machine is equipped with an agitator safety cutout. As soon as
agitator safety cutout you open the grille, the signal between the transponder and reading
(RSA) head is broken. This causes the agitator to halt and the pressure to
be dumped from the accumulator, i.e. the transfer tube will no longer
be able to switch over. In addition, the delivery pistons return to the
end position and the concrete pump halts.

Danger
Risk of injury when the agitator is operating and the transfer tube is
switching.

A defective agitator safety cutout can cause you to believe that the
machine is safe, even though this is not really the case. This can
lead to the agitator continuing to run or the transfer tube switching
over when the grille is open.

You must therefore check the function of the agitator safety cutout
before you start each pumping job.

Before acknowledging the agitator safety cutout, check that noone

is in any 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.

AP13_085_1304EN 413
 Startingup

1 2 3

AP13_085_1304EN 1

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

" Open the grille with the concrete pump running.

å The transponder signal is broken.
å The agitator must come to a halt immediately.
å The transfer tube must no longer switch over.
å The concrete pump must run to the end position and halt.

Note
In order to restart, you must first acknowledge the agitator safety
cutout toggle switch on the operating panel.

414 AP13_085_1304EN
 Startingup

4.3.4 Acknowledging the The agitator is secured against unexpected restarts. After the
agitator safety cutout agitator safety cutout has been operated, it must be acknowledged
before the concrete pump can be switched back on.

The agitator safety cutout is triggered in the following situations:

− when the grille is opened
− when the power take
off is switched off
− when the ignition is switched off

Danger
Risk of injury when the agitator is operating and the transfer tube is
switching.

A defective agitator safety cutout can cause you to believe that the
machine is safe, even though this is not really the case. This can
lead to the agitator continuing to run or the transfer tube switching
over when the grille is open.

You must therefore check the function of the agitator safety cutout
before you start each pumping job.

Before acknowledging the agitator safety cutout, check that noone

is in any danger.

You must stop work if you open the grille, but

 the agitator continues to run, or
 the transfer tube continues to switch over, or
 the concrete pump does not run to its end position.

AP13_098_1402EN 415
 Startingup

AP13_098_1402EN 1

Pos.0 Designation
1 Acknowledge agitator safety cutout in the operating panel

" Operate the Acknowledge agitator safety cutout" toggle switch

in the operating panel.

416 AP13_098_1402EN
 Startingup

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

" Bring the hydraulic fluid up to operating temperature (u50_C).

" Set the maximum pumping rate.

Note
The indicators on the filters can only be checked under load once
the hydraulic fluid has warmed up.

Please read the
Filter change" maintenance card.

Suction filter

10300200

Vacuum meter

Note
You must replace the filter element if the pointer on the vacuum
meter is in the red zone at more than 50_C fluid temperature and
atthe shortest stroke time.

AP13_029_0308EN 417
 Startingup

Pressure filter

AP13_029_0308EN 1

Pressing down the red button

" Press down the red button on the filter if it is sticking up.

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.

418 AP13_029_0308EN
 Startingup

4.3.6 Agitator The agitator hopper grille must always be closed when the pump is
in operation.

Danger
Risk of injury when the agitator is operating and the transfer tube is
switching.
When the machine is started up after the agitator safety cutout has
been actuated, the agitator safety cutout must be acknowledged
before the concrete pump can be switched back on.
Before acknowledging the agitator safety cutout, check that noone
is in any danger.

20203003

Pos.0 Designation
AgitatorOn− agitation direction away from the delivery
1
cylinder
2 Agitator Off
AgitatorOn− agitator direction towards the delivery
3
cylinder

" Check both directions of rotation of the agitator one after the
other by operating the appropriate toggle switch in the operat

ing panel.

AP13_099_1402EN 419
 Startingup

4.3.7 Gate valve There must be no pumping while the gate valve is being switched.
The gate valve would no longer be able to switch over safely.

AP13_100_1402EN 1

Pos.0 Designation
1 Open gate valve
2 Gate valve Off
3 Close gate valve

" Switch the agitator off.

" Set the output controller to min".

" Check both switch positions of the gate valve by operating the
appropriate toggle switch in the operating panel.

420 AP13_100_1402EN
 Startingup

4.3.8 Flushing water pump Depending on the machine equipment, it may be equipped with
either a Hypro" or a CRK" flushing water pump.
To prevent damage, never run the flushing water pump without water.
You may, however, perform a short function test lasting a few sec

onds without the water being connected.

Note
The agitator, gate valve and flushing water pump can not be oper
ated at the same time since they are all driven off the same hydraulic
circuit.

AP13_090_1304EN 1

No. 0 Designation
1 Flushing water pump On
2 Flushing water pump Off
3 Toggle switch: flushing water pump − agitator −
set
upfoot
4 Operating panel

AP13_090_1304EN 421
 Startingup

" Check the flushing water pump inlet screen and, if necessary,
clean it before operation.

" Switch the agitator off and switch the gate valve to neutral.

" On the operating panel(4), shift the Flushing water pump −

agitator − set
up foot" toggle switch(3) to the Flushing water
pump on" switch position(1), and check the flushing water
pump function.

422 AP13_090_1304EN
 Startingup

4.3.9 Vibrator The vibrator is electrically driven so an electrical connection must

first be made between it and the control cabinet.

1
3

4
31201000

" Check that the vibrator is functioning correctly.

Note
The vibrator will only function when the switch for the pump is on at
the control cabinet and at the remote control.

AP13_034_0303EN 423
 Startingup

4.3.10 Switching off the ma- When you shut down the machine, you must perform the following
chine tasks:

Switches off the pump Switch off the pump at the control cabinet.

" Set the output controller to min".

" Switch off all power consumers.

Shutting down the The following section describes the procedure for switching off the
motor motor.

Note
If you switch off the ignition, the control unit for the electronic engine
governor (EMR4) is still supplied with power for approx. twominutes.
During this run−down time, required data is saved in the control unit,
and the DEF lines are emptied (risk of freezing).

Caution
Do not switch off the motor when running at full load.

Only use the EMERGENCY STOP button in the event of danger.

424 AP13_107_1508EN
 Startingup

Caution
You must only disconnect or switch off the battery once the control
unit has completed its rundown time (approx. twominutes). Inter
rupting this rundown time will cause a fault in the control unit.
This fault is shown continuously in the display, which means that you
run the risk of overlooking other faults.
When you switch off the engine, you must follow the instructions
below:
 Only switch off the engine using the ignition−starter switch.
 Do not unplug the control unit connector when the power supply is
switched on (ignitionon).
 If maintenance work is to be carried out on the machine (e.g.elec
trical welding work), you must always disconnect all plugin con
nections from the control unit.

Putzmeister will not accept warranty claims for engine damage and
operating errors that result from a failure to switch off the engine ac
cording to the instructions.

AP13_107_1508EN 425
 Startingup

AP13_107_1508EN 1

Example illustration

No. 0 Designation
1 Ignition−starter switch: Engine On−Off

" Switch off the ignition(1).

å The control unit saves required data during the run−down
time (approximately twominutes).

426 AP13_107_1508EN
 Startingup

Possible faults If you interrupt the run−down time of the control unit, the following
faults may occur:

Note
Because the faults listed here are not control unit malfunctions, but
operating errors, the work involved in rectifying them is not covered
by the warranty, as stated in the general terms and conditions of
DEUTZ.

Fault Cause Remedy

Engine switched off,
DEUTZ service
Main relay switches as the battery is dis

technician rectifies
to passive state connected/switched
fault
off
The engine was
switched off using
the ignition−starter
DEUTZ service
EEPROM memory switch, but the bat

technician rectifies
fault tery was discon

fault
nected/switched off
before the run−down
time expired.

AP13_107_1508EN 427
 Startingup

428 AusgleichsseiteEN
 Transport,settingupandconnection

5 Transport, setting up and connection

This chapter contains information relating to transporting the ma

chine. Tasks required for setting up and connecting the machine are
also described.

AP06_001_1007EN 5I
 Transport,settingupandconnection

5II AP06_001_1007EN
 Transport,settingupandconnection

5.1 Transport Various methods of transporting your machine are possible. Loading
the machine onto a transport vehicle is always one method. The
other methods depend on how your machine is equipped.
− Machines with an F80 chassis can travel on public highways.
− The machine can be moved in the same way as a trailer if fitted
with an F8 chassis, but movement is restricted to the construction
site. The maximum speed at which it may be moved is 8km/h. The
machine is not authorized for use on the public highway so you will
have to transport it to the construction site on a transport vehicle.
− The machine will always have to be transported on a transport ve

hicle if it has a static frame.

5.1.1 Loading Lifting eyes will need to be fitted to the machine should you wish to
load it onto a transport vehicle. Any lifting eyes fitted to your machine
for the purpose of lifting it will be located on the top of the machine
and may be identified by their colour.

Suspended load
Raised loads may fall if they are not loaded properly or if the slings
and eyes are damaged.
You should, therefore, never walk under suspended loads.

Caution
The machine may only be loaded by crane if it is equipped with suit
able lifting eyes. Lifting equipment, lifting tackle, support trestles and
other auxiliary equipment must be reliable and safe in operation.
Make sure that the loadbearing capacity is adequate. Always lift the
machine by all its lifting eyes, otherwise too great a load could be
placed on individual lifting eyes.

The machine must be properly secured on the transport vehicle to

prevent it rolling away, slipping or tipping over.

AP06_003_1007EN 51
 Transport,settingupandconnection

5.1.2 Lifting eyes Use the lifting eyes as shown.

Note
The lifting eyes fitted to your machine for the purpose of lifting are
located on the top of the machine and are marked by their colour
(generally red).

It is best to transport the machine standing on its support legs so

that it cannot roll away.

AP06_003_1007EN 1

Suspend by all lifting eyes

1 Rope angle > 45_

" Hook a four−cable sling to the 4 lifting eyes.

Danger
The machine may begin to swing when weight is taken off the sup
port feet if it is hoisted at an angle. You must therefore always hoist
the machine vertically.

" Hoist the machine vertically.

" Place the machine on a suitable transport vehicle and lash it

down securely.

52 AP06_003_1007EN
 Transport,settingupandconnection

Suspended load
Use only appropriate lifting gear. Suspend the BSA from the lifting
eyes specified.
Never hoist the load over people. Take note of the safety regulations
for crane operations.

BSA

AP06_003_1007EN 2

4 lifting eyes

AP06_003_1007EN 53
 Transport,settingupandconnection

5.1.3 Chassis Your machine may be mounted on different chassis models or on a

static base structure, depending on the specification. The chassis
model is stated on the machine card and the maximum permitted
speed is stated on the rating plate.

5.1.4 F 8 chassis The machine may not travel on public roads if fitted with an F8 chas

sis. Towing the machine as a trailer is restricted to the construction
site or private property.

Caution
The machine must not exceed a maximum speed of 8km/h when
under tow if fitted with an F8 chassis.

You must load the machine onto a suitable transport vehicle to trans

port it to the construction site (see Loading").

5.1.5 F 25 chassis The machine may not travel on public roads if fitted with an F25
chassis. Towing the machine as a trailer is restricted to the construc

tion site or private property.

Caution
The machine must not exceed a maximum speed of 25km/h when
under tow if fitted with an F25 chassis.

54 AP06_039_1211EN
 Transport,settingupandconnection

5.1.6 F 80 chassis The machine may travel on public roads in the same way as a stan

dard trailer if fitted with an F80 chassis.

Note
Stationary concrete pumps can only be driven on public roads if they
have the appropriate approval. The driver of the tractor unit 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 cordoned off or secured by
assistants. Have the site management arrange for the removal of any
materials or equipment that hinder your approach.

Hand signals

10000331

For hand signals, see the chapter Hand signals for driving"

" Agree clear hand signals with the signaller before moving off.

AP06_039_1211EN 55
 Transport,settingupandconnection

Before moving off There are several tasks you will need to perform before joining the
public road, including the following:

Caution
If you have changed the tyres, you must retighten the wheel nuts
after approximately 50km.

See the spare parts sheet for the tightening torques.

" Check that the vehicle is safe to drive (lighting, brakes, tyre
inflation pressures, wheel nuts etc.).

" Clean the machine so that it does not soil the public roads.

" Check that the accessories are secure.

Danger
Supports extending spontaneously whilst the truck is moving can
cause serious accidents. Fit the transport security devices (such as
spring pins).

" Check to make sure that the support legs are secured for
driving.

" Observe the permissible gross laden weight.

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

56 AP06_039_1211EN
 Transport,settingupandconnection

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 load
bearing capacity is adequate.

" Be aware of the elevated position of the truck’s centre of gravity

when travelling on a slope and on ascending or descending
routes.

You must load the machine onto a suitable transport vehicle to trans

port it to the construction site (see Loading").

5.1.7 Crawler track Your machine can be towed by a tractor unit if fitted with a crawler
track.

Note
Observe the manufacturer’s operating and maintenance instructions.

The machine is neither equipped nor approved for travel on public

roads.

5.1.8 Static base structure If your machine is fitted with a stationary base structure, it can only
be moved to the construction site on a transport vehicle.

AP06_039_1211EN 57
 Transport,settingupandconnection

5.2 Hand signals for It is often necessary to have a signaller help by directing you when
driving you are driving to the set−up site on construction sites where space
is restricted. Clear hand signals must be agreed between signaller
and machine operator. Below you will find some suggestions for
hand signals to be used when driving.

Stop Extend both arms out 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

58 AP06_031_1007EN
 Transport,settingupandconnection

Drive towards the With the arm crooked, wave the

signaller palm in the direction the truck
should drive.

10000303

Drive away from the With the arm crooked, wave 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

AP06_031_1007EN 59
 Transport,settingupandconnection

5.3 Requirements for the As a rule, the site management determines the set−up site for the
set–up site machine and prepares the site accordingly.

Note
The machine operator takes responsibility for setting up the machine
safely.

" Inspect the proposed site carefully and reject the set−up site if
you have any doubts in respect of safety.

On stationary concrete pumps that are equipped with a system for

exhaust gas treatment, regeneration procedures (stationary regener

ation) are regularly triggered automatically or, if required, activated
manually.

Danger of fire
Danger of fire due to inadequate clearance from a stationary con
crete pump during the regeneration procedure.
During the regeneration procedure in particular, very high exhaust
gas and surface temperatures occur near a stationary concrete
pump (approx. 600°C).
Activate the regeneration procedure out in the open air only.
Look for a set−up site that has sufficient clearance from other ma
chines, combustible materials and flammable liquids.
Use your personal protective equipment.

510 AP06_005_1508EN
 Transport,settingupandconnection

Danger of poisoning
Injuries to the respiratory passage.
Vehicle exhaust gases contain constituents that can be deadly or
carcinogenic.
Set the machine up at an adequately ventilated site or vent the ex
haust gases away from where you are working.

" Ensure that the set−up site is adequately ventilated.

Accessibility The set−up site must be level. It must be large enough for the ma

chine to be accessible for operation and maintenance work from all
sides. You must be able to open all the guards, flaps and hoods
without obstruction.

" Ensure that there is sufficient clearance around the entire ma

chine.

Approach route The approach route must be sufficiently firm that so it can be driven
over regardless of the weather conditions. Walk along the approach
route before you drive over it. Ask for a signaller if you need to re

verse.

Space for truck The approach route to the concrete pump must be firm enough that
mixers it can be driven over by truck mixers regardless of the weather
conditions.

There must be sufficient space around the concrete pump for truck
mixers to manoeuvre and turn.

There must be sufficient space around the hopper for two truck
mixers to unload at the same time.

AP06_005_1508EN 511
 Transport,settingupandconnection

Supporting ground The supporting ground must be firm enough to absorb the forces
conducted by the support feet into the ground. There must not be
any voids or ground unevenness under the support feet.

22102802

No voids or ground unevenness under the support feet

" Always rest the support feet on support plates, timber blocks
or other suitable construction timber.

It is recommended that you select a set−up site which has been con

creted if the concrete pump is to remain on the same set−up site for
a prolonged period.

It is recommend that concrete pumps working at high−pressure and

high delivery rate are securely anchored.

512 AP06_005_1508EN
 Transport,settingupandconnection

Minimum clearance A minimum distance must be maintained from pits, slopes, excava

from pits tions etc. so that the machine cannot topple over.

45°
12100401

Minimum clearance a

The minimum clearance a" for machines with a gross weight of up

to 12 tons is 1 metre

" Maintain a distance from pits, slopes, trenches etc., when ap

proaching the set−up site.

Lighting The set−up site must be adequately illuminated in order to ensure

safe working on the machine.

" Ensure that the set
up site is adequately lit.

Draining away wash- Draining of the washing water must be ensured (e.g. using a sew

ing water age pump), and particularly if the concrete pump has been set up in
a pit or trench.

AP06_005_1508EN 513
 Transport,settingupandconnection

5.4 Setting up The machine must be level. Pay particular attention to the section
headed Requirements on the set−up site".

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

AP06_016_0110EN 1

Initial situation

" Use chocks to secure the machine against rolling.

" Wind the support wheel down and disconnect the machine
from the tractor unit.

AP06_016_0110EN 2

Lower the drawbar at the front

" Lower the drawbar as far as possible by winding up the

support wheel.

514 AP06_016_0110EN
 Transport,settingupandconnection

Note
You must extend the support feet far enough so that the wheels will
no longer be in contact with the ground when the machine is sup
ported.

AP06_016_0110EN 3

Supporting the rear

" Place timber blocks or other suitable material beneath the rear
support feet.

" Unlock the rear support feet by removing the spring pins from
the locking bolts and then removing the bolts.

" Extend the rear support feet as far as possible.

" Reinsert the locking bolts in the last possible hole and secure
them with the spring pins.

AP06_016_0110EN 515
 Transport,settingupandconnection

Note
Use only suitable lifting equipment for lifting the machine. The
support wheel is not suitable for lifting the machine.

AP06_016_0110EN 4

Raise the machine and support at the front

" Raise the machine by the drawbar sufficiently that the front
support feet can be extended to exactly the same extent as the
rear feet.

" Place timber blocks or other suitable material beneath the front
support feet.

" Unlock the front support feet by removing the spring pins from
the locking bolts and then removing the bolts.

" Extend the front support feet to the same extent as the rear
support feet and reinsert the locking bolts.

" Secure the locking bolts with the spring pins.

516 AP06_016_0110EN
 Transport,settingupandconnection

AP06_016_0110EN 5

Machine set up correctly

" Lower the machine.

Note
Recoil from the delivery line may be transmitted to the machine
under extreme operating conditions (high−pressure delivery, for
example). This recoil could jeopardize the stability of the machine.

The support feet can be anchored to the ground (concreting them in

or lashing them down with tensioning chains, for instance) to give the
machine greater stability.

AP06_016_0110EN 517
 Transport,settingupandconnection

5.5 Stationary When pumping concrete, you must only use perfect and safe deliv

delivery line ery lines, couplings and seals. The delivery lines and couplings must
be specially designed for the pressure specified on the pump rating
plate. The delivery lines are subject to wear, which is dependent
upon:
− the concrete pressure
− the concrete composition
− the delivery line material.

10
9
8
7
6

5
4
3
2
1

AP06_014_1007EN 1

No. 1 Designation
1 Pressure pipe
2 Bolted coupling
3 Reducer
4 Clamp coupling
5 Pipe bracket
6 Delivery pipe (adapter pipe)
7 Clamp coupling
8 Pipe bracket
9 Vibration damper
10 Delivery pipe (adapter pipe)

518 AP06_014_1007EN
 Transport,settingupandconnection

5.5.1 Danger zone

3m
AP06_014_1007EN 2

Danger zone for stationary delivery lines

Danger
Serious injuries may be caused by the delivery line bursting as a re
sult of a sudden increase in pressure.
Do not remain in the danger zone of a stationary delivery line.
Cover the stationary delivery line with a metal casing or timber clad
ding if persons are working in its immediate vicinity.

AP06_014_1007EN 3

Cover delivery lines

AP06_014_1007EN 519
 Transport,settingupandconnection

5.5.2 Instructions for laying The stationary delivery line can be laid horizontally over the ground,
the line or vertically or inclined against walls. The entire length of the delivery
line must be easily accessible and removable.

Note the following points when laying the delivery line:

" Lay the stationary delivery lines without stresses.

" Support the delivery line so that couplings can be easily fitted
and removed. Double wooden chocks (see illustration) are
most suitable as they allow for longitudinal and latitudinal
movement by the delivery line.

AP06_014_1007EN 4

Support the delivery lines with double wooden chocks

" Use highly wear−resistant pipes for sections which are difficult
to access.

" Begin laying the delivery line at the concrete pump as other

wise you will have to line up the concrete pump to the delivery
line.

520 AP06_014_1007EN
 Transport,settingupandconnection

AP06_014_1007EN 5

Delivery line leading away at a right angle to the concrete

pump

" Route the stationary delivery line away from the concrete pump
at right angles to it. This minimizes the effect of pump pulsa

tions which may be transmitted from the delivery line to the
pump and vice versa.

" Guide the delivery line in the direction of the arrow away from
the concrete pump. The operator’s side of the concrete pump
is then not in the danger zone.

" Fit only as−new delivery pipes near the pump, as the concrete
pressure is highest here.

" Secure couplings against spontaneous opening.

" You must also take into account any components of the deliv

ery line required for distribution and cleaning such as a T−de

livery pipe with wash−out port, scraper pig gates, transfer
tubes, gate valves etc.

AP06_014_1007EN 521
 Transport,settingupandconnection

5.5.3 Fastening Pump pulsations occur when pumping concrete. These are caused
by the pump itself and are transmitted to the delivery line system.
The stationary delivery line must be safely secured and stabilised on
the supporting ground.

Danger
There is a risk of serious injury from falling items.
Do not secure the stationary delivery line to reinforcements or scaf
folding as these can be moved and could collapse.
If you wish to secure the stationary delivery line to reinforcements or
scaffolding, check whether the scaffolding can bear the load.

Horizontal All horizontal delivery lines must be anchored on the supporting

delivery line ground.

" Use pipe brackets which are secured to a suitable supporting

ground capable of bearing the load
å The pump pulsations are reduced and the delivery line is
prevented from bending.

AP06_014_1007EN 6

Fastening the delivery line

522 AP06_014_1007EN
 Transport,settingupandconnection

Fixed point A fixed point is a 1−2m3 large, reinforced lump of concrete with a
delivery pipe secured to it or sealed inside it. It takes pump pulsa

tions from the delivery line.

" Install a fixed point near to the concrete pump.

å The pump pulsations are reduced and the delivery line is
prevented from bending.

AP06_014_1007EN 7

Elasticity of the delivery line using a fixed point

AP06_014_1007EN 523
 Transport,settingupandconnection

Vertical (angled) Vertical or angled delivery lines leading upwards or downwards must
delivery line always be fastened to the structure or background so that they are
self−supporting. The delivery line must not be supported by the
lowest pipe bend.

AP06_014_1007EN 8

Fastening the delivery line

The lowest elbow should be a thick−walled 90° cast elbow with a

radius of 1m.

524 AP06_014_1007EN
 Transport,settingupandconnection

Risers The delivery line is called a riser where it is laid in such a way that
the concrete is pumped upwards.

Gate valve The weight of the concrete in the riser exerts a force on the concrete
pump (approximately 30kg per metre of continuous pipe) when the
pump is switched off.

" Install a gate valve at the start of the riser.

å The delivery line can be closed off so that the pressure
bears on the gate valve and not on the concrete pump.

Downpipes The delivery line is called a downpipe if it is laid in such a way that
the concrete is pumped downwards.

Gate valve The concrete flows down through the delivery line under its own
weight when the pump is switched off. This causes the concrete col

umn to break off and the concrete can segregate.

" Install a gate valve at the end of the downpipe.

å The delivery line can be closed off so that the concrete
cannot flow out of the delivery line.

AP06_014_1007EN 525
 Transport,settingupandconnection

5.5.4 SK delivery line When laying Putzmeister SK delivery pipes, maintain a gap of 4mm
system between the individual pipes.

Note
Grease all couplings and seals well internally before assembly. Use
a lithium soap base multipurpose grease with the marking K2K.

4mm

AP06_014_1007EN 9

Putzmeister SK delivery line with clamp coupling, A seal and

spring pin

" Secure each clamp coupling with a spring pin.

526 AP06_014_1007EN
 Transport,settingupandconnection

5.6 Rod side – piston side The hydraulic hoses on the drive cylinder must be connected for rod
feed side or piston side feed, depending on the job in hand. The machine
is connected up for rod side feed when it is delivered.

Normal delivery The drive cylinders must be fed on the rod side to pump a large
quantity of concrete in a short time.

High-pressure The drive cylinders must be fed on the piston side to pump concrete
delivery at high pressure.

Danger of explosion
Piston side feed gives a higher concrete pressure. You must there
fore only use delivery lines suitable for high−pressure delivery if you
are using piston side feed.

Changing over The procedure for changing the feed to the drive cylinders is as fol

lows:

" Shut the machine down and secure it against unauthorized or

accidental starting.

" Dump the pressure in the hydraulic system and in the accumu

lator completely before you start working on the hydraulic sys

tem.

Caution
Cleanliness is of the utmost importance in the maintenance of hy
draulic systems. Prevent any type of dirt or contamination from enter
ing the system. Even small particles may cause valves to be scored,
pumps to seize and throttle, and control bores to become blocked.

AP06_071_1411EN 527
 Transport,settingupandconnection

1 2

AP06_071_1411EN 1

No. 0 Designation
1 Rod side feed
2 Piston side feed

" Place a container beneath the ports you are changing over to
catch the fluid.

Environmental protection
All operating equipment and functional fluids, e.g. oils (including bio
logically degradable oils), filters and auxiliary materials must be
carefully collected and disposed of separately, both from each other
and from other waste. Different categories of oil must also be kept
separately from each other. Nationally and regionally applicable dis
posal regulations must be observed for these materials.

" Change over the hydraulic hoses as illustrated.

Danger
Only top up with new hydraulic fluid.

" Top up the hydraulic fluid in the hydraulic fluid reservoir by the
same amount that has escaped.

528 AP06_071_1411EN
 Transport,settingupandconnection

5.7 Flushing water pump Depending on the machine specification, it may be equipped with
either a Hypro WP 50 or a CRK 4−160.

Note
The water supply can be hampered by:
 the water hose diameter being too small
 the water pressure being too low for a significant head
 the hoses being pinched or kinked
 a damaged hose or
 several consumers using the same water supply at once

Flushing water pump

Hypro WP 50
1

AP06_056_1008EN 1

No. 0 Designation
1 Claw coupling for high−pressure water hose
2 Claw coupling for the water supply

Note
Make sure that you connect the flushing water pump with a sufficient
supply of water (50litres per minute).

AP06_056_1008EN 529
 Transport,settingupandconnection

Flushing water pump

CRK 4–160

2
1

AP06_056_1008EN 2

No. 0 Designation
1 Claw coupling for high−pressure water hose
2 Claw coupling for the water supply

Note
Make sure that you connect the flushing water pump with a sufficient
supply of water (160litres per minute).

530 AP06_056_1008EN
 Pumpingoperations

6 Pumping operations

This chapter contains information regarding the operation of the

machine for pumping. You will learn what steps are required for
pumping and cleaning.

AP07_026_9710EN 6I
 Pumpingoperations

6II AP07_026_9710EN
 Pumpingoperations

6.1 Preconditions You must have carefully completed the operations required to start
up and set up the machine before you start pumping.

Before you fill the hopper with concrete and pump it through the
delivery line, make sure that:
− the machine is functioning,
− the delivery line is designed to withstand the relevant concrete
pressure and
− the delivery line is correctly laid.

Note
If a malfunction occurs during the pumping operation, you must stop
your work and have the cause of the fault rectified by qualified per
sonnel at your company or by our After Sales Service personnel.

Timely detection and rectification of damage can prevent lengthy

downtimes and high repair costs.

AP07_069_1007EN 61
 Pumpingoperations

6.1.1 Remote control Depending on your machine’s equipment, you can operate it
− with the radio remote control,
− with the cable remote control or
− directly on the machine in emergency operation.

Caution
Carry the remote control in such a way that no control elements
canbe actuated unintentionally. Do not damage the remote control
cable. Malfunctions may otherwise occur.
Never put the remote control down when the machine is ready for
operation. If this is unavoidable in exceptional cases, you must
switch off the remote control, disconnect it and lock it away.

Danger
Risk to life from unintended machine movements. The range of
aradio remote control is great enough for the machine to receive
control commands (e.g. from a great distance, from inside enclosed
spaces), even without visual contact. In such cases, signallers MUST
be used, and must remain in contact with the machine operator
using suitable means, and have visual contact with the site of
concrete placement, work and danger zones and the machine.

62 BP07_051_1109EN
 Pumpingoperations

6.2 Hand signals for It is particularly important that the machine operator at the concrete
pumping pump and the concreting gang working at the placement site can
communicate with each other if accidents are to be avoided when
pumping. Communication is particulary important in long−distance
and high−rise pumping where the machine operator cannot see the
site of concrete placement. Communication may be via unambiguous
and non−interchangable:
− acoustic signals such as a horn, two−way radio, field telephone
etc.
− optical signals such as light signals, hand signals etc.
− a combination of optical and acoustic signals

Suggestions for the most important hand signals are made in this
chapter. They are based on DIN24081, DIN33409 and guideline
RI/08.90/2 issued by the German Construction Employers’ Liability
Insurance Association, amongst other guidelines. The direction of
movement is specified from the machine operator’s direction of view.

EMERGENCY STOP Extend both arms outwards

and move up and down
quickly.

10000308

Slow Place a fist on the helmet.

10000307

AP07_029_0905EN 63
 Pumpingoperations

Increase output/ The thumb of one hand points

Start pumping upwards. The palm of the
other hand is held over it.

10000327

Reduce output The thumb of one hand points

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

10000328

Reverse pumping The crooked elbow of one arm

points downwards into the
palm of the other hand.

10000329

Stop pumping Grip both hands together over

the head.

10000330

64 AP07_029_0905EN
 Pumpingoperations

6.3 Filling the machine Your machine is driven by a diesel engine. The fuel tank is integrated
with fuel into the truck superstructure, and its filler pipe is located on the left
side of the machine. You can use the filler opening to refuel the ma

chine when it is switched off.

Note
Refill the fuel tank in good time, as otherwise you will have to bleed
the fuel line to the diesel engine.

The engine and its exhaust after treatment system are coordinated
with one another and form a complete engine system.

Caution
Damage to the complete engine system by not complying with the
engine manufacturer’s requirements and recommendations for func
tional fluids.
Diesel engines equipped with SCR, DPF and DOC types of exhaust
after treatment systems must only be filled and operated with sul
phur−free diesel (in accordance with DIN51628 and EN590).
Failure to observe this means that the engine manufacturer cannot
guarantee the operational safety and life of the exhaust after treat
ment system.
Only fill the machine with fuel when the engine is switched off.
Pay attention to cleanliness when filling the machine with fuel. Do not
spill a single drop of fuel.
Observe the requirements and recommendations for operating ma
terials such as lubricating fluid, permitted fuels, coolant and diesel
exhaust fluid in the engine manufacturer’s documentation.

AP07_080_1501EN 65
 Pumpingoperations

6.4 Filling the DEF con- This machine is fitted with an exhaust after treatment system. Ex

tainer haust gas is treated using a diesel exhaust fluid (DEF), e.g. Ad

Blue". Once the warning symbol Fill level of the DEF container"
lights up yellow, fill the DEF container via the filler opening (see the
engine manufacturer’s documentation).

Note
Fill up the DEF container in good time (when the
Fill level of the DEF
container" warning symbol lights up yellow) to prevent the engine
power from being reduced.

Caution
Damage to the SCR system caused by diesel exhaust fluid (DEF)
impurities.
Impurities in other media (e.g. diesel) damage the SCR system.
Dilution of the diesel exhaust fluid impairs DEF quality and exhaust
gas treatment, and therefore reduces the power of the engine (see
engine manufacturer’s documentation).
Only fill the DEF container when the engine is switched off. Ensure
cleanliness.
Only fill the DEF container with diesel exhaust fluid specified by the
engine manufacturer, because otherwise the DEF quality and ex
haust gas treatment will become poor.

66 AP07_077_1501EN
 Pumpingoperations

Caution
Danger of burning when handling diesel exhaust fluid.
Diesel exhaust fluid is an ultra−pure urea solution that has a caustic
effect on the skin and eyes.
Use your personal protective equipment when handling diesel ex
haust fluid.
Avoid skin contact with diesel exhaust fluid. Any residue must be
washed off with water.

Caution
Corrosion damage and damage to electrical and electronic compo
nents within the engine compartment caused by contact with DEF.
Fill the DEF container carefully so that the engine compartment is not
contaminated with DEF. Contaminated components must be washed
with water.

AP07_077_1501EN 67
 Pumpingoperations

AP07_077_1501EN 1

Example illustration: Filling the DEF container

Pos.0 Designation
1 Fill level warning symbol for the DEF container (yellow)
2 DEF container

68 AP07_077_1501EN
 Pumpingoperations

AP07_077_1501EN 2

Example illustration: DEF container

Pos.0 Designation
1 DEF container
2 Lid

" Switch off the remote controls.

" Switch the pump off.

" Switch the diesel engine off.

" Secure the machine against being started up unintentionally.

" Unscrew the lid(2) from the filler opening of the DEF con

tainer(1).

" Fill the DEF container(1) with diesel exhaust fluid.

" Screw the lid(2) back onto the filler opening of the DEF con

tainer(1).

AP07_077_1501EN 69
 Pumpingoperations

6.5 Considering concrete Properties of the concrete such as its consistence and grading curve
properties are decisive factors for the optimum fill level of the delivery cylinders.
The fill level influences the level of efficiency of the pump, i.e. the
output per stroke.

Saturated mix

2
1

11000401

No. 0 Description
1 Aggregate
2 Cement paste
3 Boundary layer

Note
A low fill level will be achieved in the delivery cylinder if the consist
ence is too stiff and the grading curve of the aggregates is unfavour
able (low sand content, broken material). In such cases, reducing
the speed of pumping can increase the output.

610 AP07_031_0304EN
 Pumpingoperations

6.6 Filling the agitator

hopper

AP07_027_0303EN 1

Always fill the agitator hopper with concrete

up to the mixer shaft.

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
reason.

You should therefore always fill the agitator hopper with concrete up
to the mixer shaft during pumping operations.

AP07_027_0303EN 2

Danger from escaping compressed air

AP07_027_0303EN 611
 Pumpingoperations

6.7 Inserting the

stop plates

AP07_050_0303EN 1

Caution
The stop plates must be fitted in the water box during pumping
operations.

612 AP07_050_0303EN
 Pumpingoperations

6.8 Starting pumping The process from the start of forwards pumping to the time at which
a continuously flowing concrete stream exits from the delivery line is
known as starting to pump. This may be at the start of the site use, or
also after breaks in pumping.

The entire delivery line must be wetted at the start of pumping oper

ations.

11000501

Starting pumping with thin concrete

" Insert two sponge balls into the delivery line through the
wash−out port.

" Pour approximately 0.5 m3 thin concrete into the hopper.

" Switch the agitator on.

" Slowly pump the concrete into the delivery line.

Starting to pump with thin concrete is completed when the two

sponge balls and a solid concrete stream exit from the delivery line.

Note
You must begin pumping with a cement−water mixture (grout) if the
delivery lines are new, or if the delivery line has not been used for a
long time.

AP07_032_9710EN 613
 Pumpingoperations

6.9 Pumping Correct mixing of the concrete influences pumping performance.

" Mix the concrete vigourously in the truck mixer at maximum

speed. Ensure that the concrete mix is uniformly prepared.

" Concrete additives (deflocculants, set retarding admixtures)

must be mixed in for at least 4minutes after they are added.

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

" Switch the agitator on.

" Begin delivery.

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

A machine driven by a diesel engine can be run more economically

by selecting engine speed and output regulation such that the
engine does not rev too highly when under low load.

614 AP07_034_9710EN
 Pumpingoperations

6.9.1 Monitoring The displays of the monitoring instruments must be kept under
observation during pumping operations.

1 2

3
10301100

No 0 Designation
1 Vacuum meter
2 Hydraulic fluid temperature gauge
3 Hydraulic pressure gauge

" Check all displays for the monitoring instruments:

− Vacuum meter: the indicator must not be in the red zone. An indi

cator in the red zone implies that the associated vacuum filter is
contaminated or the hydraulic fluid is too cold.
− Fluid temperature gauge: the fluid temperature must not exceed
90_C.
− Hydraulic pressure gauge: the value indicated must not exceed
the maximum value specified on the machine card.

AP07_035_9710EN 615
 Pumpingoperations

Note
You must repeat these checks at regular short intervals all the time
the machine is running.

Danger
The machine must be switched off every time a fault is indicated. All
faults must be rectified immediately, otherwise the guarantee will be
invalidated.

" Check the bearings and seals on the switching shaft, the pres

sure connection and the agitator shaft at regular intervals.

" Lubricate the machine as required.

Note
The bearings and seals must be replaced as soon as a cement−
coloured fluid and grease mixture or slurry begins to escape.

616 AP07_035_9710EN
 Pumpingoperations

6.9.2 Transfer tube

damping

20203903

Hare: damping valve switch position open

Snail: damping valve switch position closed

" The damping valve is used to control the switching speed of

the transfer tube.

Note
You must close the damping valve when you are pumping soft
consistence concrete (snail symbol) as otherwise the transfer tube
switches over too harshly.

You must open the damping valve (hare symbol) when you are
pumping stiff consistence concrete as the concrete has a damping
effect.

AP07_044_0411EN 617
 Pumpingoperations

6.9.3 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 is insufficiently wetted
− transfer tube is leaking
− lines are leaking
− leavings in the transfer tube and delivery line
− unsuitable concrete composition
− segregated concrete
− set concrete

Caution
In the event of blockages, pump the concrete immediately back into
the agitator hopper and mix it up. You can switch over to forwards
pumping when the delivery cylinders and the transfer tube are
switching over automatically again without problem. Begin pumping
again with care.

618 AP07_037_9710EN
 Pumpingoperations

6.9.4 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 the vibrations of the machine. Note the following points if
breaks are unavoidable:
− Never leave the delivery line under pressure.
− Relieve the delivery line during short breaks in delivery by reverse
pumping briefly (2−3 strokes). Move the concrete at short intervals
by forward and reverse pumping.
− You should avoid breaks when pumping concrete with a low water
retentivity (tendency to bleeding) as the vibrations can segregate
the concrete. You must always leave the pump switched to reverse
pumping when you begin pumping again and wait for the transfer
tube to switch across fully on both sides. Only then can you switch
over to forwards pumping again.
− Pump the concrete back into the agitator hopper before long
breaks in pumping. You must mix the concrete again before you
recommence pumping.

Note
Reverse pumping is only possible for a few pump strokes, otherwise
the hopper overflows.

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.

AP07_038_9710EN 619
 Pumpingoperations

6.9.5 Engine Do not exceed the permissible engine speed specified in the ma

chine card and on the machine rating plate. Always set the engine
speed higher than the vibrating speed. Do not shut down the engine
immediately after periods of heavy engine loading, but first allow it to
cool down at idling speed.

6.9.6 Overheating During normal pump operation, the temperature of the hydraulic fluid
is between 70_C and 80_C.
The following may cause the hydraulic fluid to overheat, particularly
ifseveral factors coincide:
− continuous operation under high load
− high ambient temperatures
− too little fluid in the hydraulic system
− dirty hydraulic fluid radiator
− insufficient radiator ventilation
− hydraulic fluid radiator sucking in hot exhaust gases
− excess pressure as a result of a blockage
− too little water in the water box.

All pumps have a thermo−electrical cut−out. The pump is automati

cally shut down if the fluid heats up to over 90_C. The engine keeps
running to provide cooling and a red indicator lamp lights up on the
control cabinet. Proceed as follows to prevent a shut−down in the
middle of pumping when a fault is indicated:

" Reduce the output.

" Fill the water box with fresh water as soon as the fluid tempera

ture rises above 80_C.

620 AP07_056_0304EN
 Pumpingoperations

Cooling

10600200

" Change the water frequently if the temperature continues

torise.

" Trace the cause of fluid overheating and rectify it.

Additional cooling If necessary, you can cool the drive cylinders with a water jet if the
measures described above are not adequate.

10600400

" Direct the water jet at the drive cylinders and piston rods for
the drive cylinders.

Caution
Never use sea water or salt water for cooling. Otherwise the chrome
layer on the delivery piston rods and delivery cylinders will be
destroyed.

AP07_056_0304EN 621
 Pumpingoperations

6.9.7 Exhaust after treat- This section describes how to operate the exhaust after treatment
ment system system.

Danger
Risk of burning when touching components that conduct exhaust
gases.
During the DPF regeneration procedure/stationary regeneration, ex
tremely high exhaust gas and surface temperatures arise at the ex
haust gas treatment system.
You are not permitted to use the machine during stationary regener
ation.
Maintain a sufficient distance from the exhaust after treatment sys
tem. Use your personal protective equipment.

Note
For details on how to work and handle the exhaust after treatment
system, observe the engine manufacturer’s documentation (see the

Exhaust after treatment system" section in the
General technical
description" chapter).

Note
The warning strategy of the SCR system complies with the relevant
national codes of practice.
The following emission−relevant faults are therefore displayed:
 Fill level of the DEF container
 DEF quality and exhaust gas treatment
 DPF regeneration
 Manipulation
(See the
Menu−independent warnings" section in the
General
technical description" chapter).

622 AP07_079_1509EN
 Pumpingoperations

Automatic DPF regen- The diesel particulate filter (DPF) with passive regeneration continu

eration ously regenerates automatically (without the user having to do any

thing) if the filter load has reached 100% of the nominal soot load.
The continuous DPF regeneration procedure lasts approx. 40 min

utes and takes place at exhaust gas temperatures of approx. 580°C
on the DOC/DPF module.

You can switch off/prevent the DPF regeneration procedure at the

central module control cabinet as follows; for example if the machine
is located in a low building:

" Press the Regeneration On − Off" toggle switch again or

switch the Pumping operations/Enable regeneration" toggle
switch from the Enable regeneration" switch position to the
Pumping operations" switch position.

Note
If you interrupt a DPF regeneration, the diesel particulate filter con
tinues to be loaded. As soon as the message text
DPF regeneration
required" is displayed in the EGD, you must manually switch on the
DPF regeneration.

AP07_079_1509EN 623
 Pumpingoperations

Stationary regener- If the filter load has reached 100% of the nominal soot load on the
ation diesel particulate filter (DPF), DPF regeneration is required.
A yellow DPF regeneration" warning symbol lights up in the EGD,
along with the message text DPF regeneration required". The DPF
regeneration/stationary regeneration must be switched on manually.
DPF regeneration lasts approx. 40 minutes and takes place at ex

haust gas temperatures of approx. 580°C on the DOC/DPF module.

Danger of fire
Danger of fire due to an inadequate clearance from a stationary con
crete pump during the DPF regeneration procedure.
During the DPF regeneration procedure in particular, very high ex
haust gas and surface temperatures occur near a stationary con
crete pump.
Activate the DPF regeneration procedure out in the open air only.
Look for a set−up site that has sufficient clearance from other ma
chines, combustible materials and flammable liquids.
Use your personal protective equipment.

Note
If you interrupt a DPF regeneration procedure because you see a
yellow
DPF regeneration" warning symbol, the exhaust gas treat
ment system will activate further escalation levels (depending on the
length of the pumping operation).
The result is that power reduction level 2 is activated in the last es
calation level if there is a red warning symbol
DPF filter maintenance
required". Pumping operations and DPF regeneration are no longer
possible.
A service employee from the engine manufacturer must replace the
DPF filter.
The engine can only be enabled using service software from the en
gine manufacturer (SERDIA service tool).

624 AP07_079_1509EN
 Pumpingoperations

Note
The engine oil becomes diluted with fuel after each stationary regen
eration. For this reason, the quality of the engine oil is monitored.
When the yellow
Engine oil change required" warning symbol lights
up in the EGD, you must carry out an engine oil change.

Note
As soon as the
DPF regeneration" warning symbol lights up yellow
in the EGD of the central module control cabinet, you must
man
ually" start the regeneration procedure/stationary regeneration on the
central module control cabinet.
The regeneration procedure can only be started
manually" if the fol
lowing conditions are met:
 You have positioned the machine in the open, in an area with suffi
cient distance from other machines, combustible materials and
flammable liquids.
 The engine speed must be reduced to idling speed.
 The delivery rate must be reduced to 0%.
 The engine must be in a no−load state.
 The engine must be warm (coolant temperature higher than 70°C
and exhaust gas temperature downstream of the DOC lower than
250°C).
 The SCR system for reducing nitrogen oxide (NOx ) must be active.
 The
Fill level of the DEF container" warning symbol must display a
level greater than 15%.
 The DEF container must not be frozen.

If all of the above−mentioned conditions have been met, you can

start the DPF regeneration procedure at the central module control
cabinet.
The DPF regeneration procedure takes approx. 40 minutes.

You can switch on the DPF regeneration procedure on the central

module control cabinet as follows:

" Switch the Pumping operations/Enable regeneration" toggle

switch from the Pumping operations" switch position to the
Enable regeneration" switch position.

" Press the Regeneration On − Off" toggle switch to the Regen

eration On" switch position

AP07_079_1509EN 625
 Pumpingoperations

6.9.8 Restarting Proceed as follows if the pump has nevertheless switched off
because of overheating:

" Set the output controller to min".

Note
Never switch the engine/motor off, as the radiator must remain in
operation.

" Refresh the water in the water box.

" Wait until the fluid has cooled if you are not able to find the fault
immediately.

" Once the red indicator lamp has extinguished, switch the
pump back on and continue pumping slowly at reduced
output.

" Determine the cause of the fluid overheating once pumping

operations have been completed and rectify the fault.

626 AP07_058_0303EN
 Pumpingoperations

6.10 Cleaning Concrete leavings that are deposited inside the delivery line or
transfer tube can cause damage, will accumulate and reduce the
cross section. A clean delivery line and transfer tube is therefore in

dispensable if you wish to be able to start pumping without problems
on the next job.

Concrete leavings deposited around the wear ring can impair its
function. For this reason, thorough flushing of the wear ring is re

quired at the end of a job, unless the next pumping job follows within
30−60minutes.

Cleaning instructions

Caution
To ensure that you do not damage the paint and other surfaces of
your machine, you must observe the following:
 Never use sea water or other water containing salt for cleaning
purposes. You must rinse off any sea water that is deposited on
the machine.
 Do not use any aggressive cleaning agents.
 The water used for washing must not be hotter than 50 °C
(122°F).
 The spray nozzle must be held at least 40−50cm from the paint
surface.

You must also observe the following during the first 8weeks of oper
ation:
 During this time, you must not use any steam jet equipment since
the paint is not fully cured.
 Furthermore, you may only use cold water for cleaning during this
period.

Lock the remote control unit away during cleaning operations. The
remote control unit does not have a watertight casing. Perform the
machine functions required during cleaning operations from the con
trol cabinet.

AP07_040_1009EN 627
 Pumpingoperations

Concrete leavings You should always find an appropriate use for the concrete leavings
to help in environmental protection.

Environmental protection
The concrete leavings should be used on the construction site. If this
is not possible, the concrete leavings should be used as building
rubble or be recycled.

We recommend that you use the Putzmeister
Leavings sheet" to

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

If the concrete is not to be used, you should bend a length of rein

forcing steel into a hook and insert it in the concrete. Once the con
crete has set, you can transport the lump of concrete away using a
site crane.

628 AP07_040_1009EN
 Pumpingoperations

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

The automatic agitator cut−out must operate correctly if it is never

theless necessary to open the grille.

Due to technical reasons, the hopper flap at the bottom of the

hopper cannot be secured. There is a risk of injury by crushing or
loss of limb by shearing if you reach inside. It is prohibited to reach
through the hopper flap into the hopper from below.

AP07_040_1009EN 1

Do not reach into the hopper.

Compressed air cleaning

Danger
There is an increased risk of accident when cleaning with com
pressed air. The cleaning operation must only be carried out by a
specialist or under expert supervision. Putzmeister accepts no liabil
ity for damage caused by cleaning with compressed air, if performed
incorrectly. All persons participating in the cleaning procedure must
be instructed in the safety regulations.

AP07_040_1009EN 629
 Pumpingoperations

6.10.1 Preparations We recommend that you carry out the preparations described below
for 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

otheraccessories

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.

630 AP07_041_9712EN
 Pumpingoperations

Catch basket You must use the catch basket if you wish to force the concrete out
of the end of the pipe using water pressure or compressed air. It
must be designed such that the concrete can flow out unhindered,
but that the sponge ball (cube, pig) is trapped and that this simulta

neously seals off the delivery line.

Danger
A catch basket on the end of the delivery line is an absolute require
ment if you are forcing the concrete out using compressed air, as
otherwise there is a risk of injury from the wash−out sponge and
concrete as they are expelled.

The use of the catch basket is recommended when water is used to

force out the concrete to ensure that the delivery line is sealed off
and no water can escape.

4
31201501

1 Coupling
2 Catch basket (closed pipe section)
3 Spring pin (on both sides)
4 Catch bracket

AP07_041_9712EN 631
 Pumpingoperations

Wash−out adaptors The wash−out adaptor is used when the machine is cleaned using
water under pressure or compressed air.

Danger
The wash−out adaptor must not be fitted to the delivery line while
pump is running as the wash−out connections and shut−off valves
are not designed to withstand the pressure of the concrete pump.
The cleaning connection can only be used for cleaning up to a maxi
mum water or air pressure of 10bar.

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 under pressure or compressed air
4 Shut−off valve for connection
5 Pressure dump bend
6 Dump cock

632 AP07_041_9712EN
 Pumpingoperations

T−delivery pipe with The T−delivery pipe with wash−out port can be used when cleaning
wash−out port with water under pressure. It allows the wash−out sponges to be
inserted quickly.
It traps the wash−out sponge in suction cleaning.

2
1

AP07_041_9712EN 1

1 T−delivery pipe with wash−out port

2 Wash−out port lid

Danger
Make sure that the T−delivery pipe is also designed for the pressure
stated on the pump rating plate.

You must only open the wash−out port lid once the pressure in the
delivery line has been dumped.

AP07_041_9712EN 633
 Pumpingoperations

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

634 AP07_041_9712EN
 Pumpingoperations

Mark the water hose The best way to clean the wear ring and seal ring on the transfer
tube is to rinse this area with water for some time from close up. You
must mark the water hose as described below to ensure that the
hose does not get cut by the switching transfer tube during cleaning.

Danger
The machine must be switched off and the hydraulic system, includ
ing the accumulator, fully depressurized when you are measuring the
hose length required, as otherwise there is a risk of injury as the
transfer tube switches over.

AP07_041_9712EN 2

1 Adhesive tape marking

" Measure the hose length required on the outside of the transfer
tube. The nozzle on the hose should be located shortly before
the seal ring so that concrete leavings are washed away from
the area around the wear ring and seal ring when the nozzle is
set to spray.

" Mark the measured length on the hose with adhesive tape, or
similar.

AP07_041_9712EN 635
 Pumpingoperations

6.10.2 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
delivery line isrecommended for the delivery lines listed. The symbols used in
the summary are explained below. The cleaning procedures are
described in the following sections.

The delivery line is connected to the concrete pump.

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 con

crete pump. The leavings are forced forwards from the
start of the delivery line to the site of concrete place

ment using an external force (compressed air or water
under pressure). Cleaning is from the start of the deliv

ery line to the site of concrete placement.

The delivery line has been disconnected from the con

crete pump. The leavings are forced backwards from
the site of concrete placement to the start of the delivery
line to using an external force (compressed air or water
under pressure). Cleaning is from backwards from the
site of 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

636 AP07_042_9712EN
 Pumpingoperations

Overview of the cleaning procedures for the stationary delivery line

Leavings
from

Delivery line to

Method of
cleaning

Compressed air

Horizontal line Water under pressure

Suction cleaning

Compressed air only with

special
Riser Water under pressure equipment

Suction cleaning

Compressed air only with

special
Downpipe Water under pressure equipment

Suction cleaning

AP07_042_9712EN 637
 Pumpingoperations

Suction cleaning Suction cleaning is the simplest and least hazardous method of
cleaning a riser. The method is described below.

" Pump the agitator hopper out until the concrete is at the level
of the top of the delivery cylinder tubes.

" Then switch the pump off.

12500100

Inserting a water−soaked wash−out sponge

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

the delivery line at the site of concrete placement.

" Switch the pump to reverse pumping.

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

Check for the

wash−outsponge

AP07_043_9712EN 1

Tapping on the delivery line with a hammer handle

" Tap on the delivery line with a piece of hardwood (hammer

handle) just ahead of the cleaning eye during the washing out
process.

638 AP07_043_9712EN
 Pumpingoperations

Note
Tapping produces deep dull noises there is concrete in the delivery
line. Tapping will yield high, clear sounds as soon as the concrete
and wash−out sponge have passed the point at which you are
tapping.

Use only a hammer handle to tap on the delivery line, as otherwise

the pipe may be damaged.

" Switch the pump off as soon as the wash−out sponge has
passed the point at which you are tapping.

Trapping the
wash−outsponge

AP07_043_9712EN 2

Turn the wash−out port lid round

" Open the wash−out port on the T−delivery pipe, turn the
wash−out port lid round and close it again with the pin pointing
inwards.

" Switch the pump back to reverse pumping.

å The wash−out sponge will be trapped on the pin of the
wash−out port lid.

" Then switch the pump off.

" Open the wash−out port lid and remove the wash−out sponge.

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

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

AP07_043_9712EN 639
 Pumpingoperations

High–pressure High−pressure water cleaning, which is more thorough, but more

water cleaning time−consuming than suction cleaning, is described below.

" Pump out the agitator hopper as far as possible.

" Switch the pump over to Reverse pumping" and relieve the
pressure on the delivery line by 1 or 2 strokes of reverse
pumping.

" Switch the pump off.

Introducing the
wash−out sponge

1 2

AP07_045_9712EN 1

1 Prepared pipe section for cleaning

2 Wash−out sponges being introduced

" Push two or three water−soaked wash−out sponges into the

wash−out port and close the port or fit the pipe section pre

pared for cleaning into the delivery line.

" Hose down the hopper with water.

" Fill the agitator hopper with water.

" Switch the pump to Forwards pumping".

å The water forces the concrete in the delivery line towards
the end of the delivery line.

" Top up the water in the hopper in good time (on longer delivery
lines) before air is sucked in.

" Pump until the wash−out sponges exit at the end of the delivery
line. Take care to ensure that the water flowing behind it does
not run into the formwork.

" Then switch the pump to reverse pumping so that the washing
water can flow out of the delivery line.

640 AP07_045_9712EN
 Pumpingoperations

Cleaning with an The principle of this method of cleaning is similar to that for high−
auxiliary pump pressure water cleaning. This involves, however, separating the
delivery line from the concrete pump and replacing this with an
auxiliary pump such as a high density solids pump (KOV) or a
wash−out adaptor with high−pressure water pump.

Note
Any high−pressure water pump you might be using must have a
sufficient volumetric flow rate of water.

" Pump out the agitator hopper as far as possible.

" Switch the pump to Reverse pumping" and relieve the pres

sure on the delivery line by 1 or 2 strokes of reverse pumping.

" Switch the pump off and then remove it from the delivery line.

" Now attach the auxiliary pump to the delivery line or use the
wash−out adaptor with high−pressure water pump.

AP07_046_9712EN 641
 Pumpingoperations

Introducing the
wash−out sponge

1 2

AP07_046_9712EN 1

1 Prepared pipe section for cleaning

2 Wash−out sponges being introduced

" When using an auxiliary pump, push two or three water−

soaked wash−out sponges into the wash−out port and close
the port or fit the pipe section prepared for cleaning into the
delivery line.

" When using a high−pressure water pump, push two or three

water−soaked wash−out sponges into the wash−out port and
then connect it to the delivery line.

" Connect the water for the auxiliary pump or high−pressure

water pump.

" Switch the pump to Forwards pumping".

å The water forces the concrete in the delivery line towards
the end of the delivery line.

" Pump until the wash−out sponges exit at the end of the delivery
line. Take care to ensure that the water flowing behind it does
not run into the formwork.

642 AP07_046_9712EN
 Pumpingoperations

6.10.3 Hopper, delivery One possible method of cleaning the hopper, the delivery cylinder
cylinder and and the S transfer tube is described below.
S transfer tube

Note
If the machine is fitted with an agitator safety cutout, the agitator is
halted and the transfer tube no longer switches over as soon as you
open the grille. In addition, the delivery pistons return to the end
position and the concrete pump halts. You must close the grille to
restart the concrete pump.

Danger
In no event should you insert the water hose, the spray gun or other
objects through the grille into the hopper to spray out the delivery
cylinders. Such objects may be trapped by the transfer tube as it
switches over and become damaged. The objects may be caused to
fly about, thereby causing an injury to you or other persons.

Drain off the leavings

ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ
ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ
ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ
ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ
ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ
ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ
ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ
ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ
ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ
ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ

AP07_047_9904EN 1

Lay the sheet down

" Place the Putzmeister leavings sheet beneath the hopper.

" Open the hopper flap beneath the hopper and let the leavings
flow out of the hopper.

AP07_047_9904EN 643
 Pumpingoperations

" Switch the pump over to reverse pumping.

å This pumps the leavings out of the delivery cylinders into
the hopper and thus out of the hopper opening.

30000500

Hoisting the concrete away

Caution
You may only hoist a maximum of 0.5m 3 concrete (approxi
mately1200kg) using the Putzmeister leavings sheet.

" Hoist away the concrete in the Putzmeister leavings sheet.

644 AP07_047_9904EN
 Pumpingoperations

Spray out delivery

cylinder
ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ
ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ
ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ
ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ
ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ
ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ
ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ
ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ
ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ
ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ

AP07_047_9904EN 2

Spray out the transfer tube and delivery cylinder with the concrete pump running slowly
in reverse

" Allow the concrete pump to run slowly in reverse.

" Spray the transfer tube out carefully downwards from the pres

sure connection. Slowly insert the hose up to the marking as
you do this (see the Mark water hose" section).

AP07_047_9904EN 645
 Pumpingoperations

AP07_047_9904EN 3

Insert the water hose into the transfer tube as far as the marking

" Hold the water hose in this position, introduced as far as the
marking, for several minutes, until only clean water runs out.
å This will flush out the two delivery cylinders alternately.

" Carefully spray out the hopper using a hose.

" Hose down all components that have come into contact with
concrete.

646 AP07_047_9904EN
 Pumpingoperations

Check sealing gap You should check the seal gap between the transfer tube and wear
ring following cleaning. The gap S" must be 1.5 to 2mm, if not the
transfer tube must be readjusted.

Maintenance card: Adjusting the S transfer tube

1 2 3 4
AP07_047_9904EN 4

1 Transfer tube
2 Thrust ring
3 Wear ring
4 Spectacle wear plate

" Check the gap S" between the transfer tube and wear ring.

Note
The gap between the transfer tube and the wear ring must be 1.5 to
2mm.

AP07_047_9904EN 647
 Pumpingoperations

Cleaning the gap After each pumping operation, you must clean the transfer tube
between the transfer bearing thoroughly to prevent any concrete encrustation in the
tube bearing and the transfer tube bearing.
S transfer tube

1 2 3

5 4

AP07_068_1007EN 1

No. 0 Designation
1 S transfer tube
2 Areas that must be cleaned
3 Pressure connection
4 Lubrication points
5 Transfer tube bearing

" Carefully spray out the areas to be cleaned(2) on the pressure

connection(3) and on the transfer tube bearing(5).

" Immediately after cleaning, use the lubrication point

provided(4) to grease the transfer tube bearing(5).
å Grease is visible between the S transfer tube(1) and
transfer tube bearing(5).

648 AP07_068_1007EN
 Pumpingoperations

6.10.4 Post-cleaning Once the delivery line, hopper, delivery cylinders and S transfer
procedure tubehave been washed out, you must thoroughly rinse down all
other parts of the machine that have come into contact with con

crete. Concrete that is not washed off immediately can attack the
paint, especially if aggressive concrete additives have been used.

Caution
The delivery line, water box, water tank and water pump must be
drained fully if there is a risk of freezing. The water box must also be
drained at normal temperatures during longer breaks in pumping,
e.g. overnight and at weekends.
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.

AP07_048_1007EN 649
 Pumpingoperations

" Clean all seals and the seal seats.

" Grease the seals before replacing them.

" Clean the remaining parts of the machine by rinsing down

withwater.

" At the lubrication point provided, grease all of the bearing

points in the hopper area immediately after washing it out.
å Grease is visible on the lubrication point.

" Grease all of the exposed piston rods.

" Grease the interior surfaces of the delivery cylinder.

" Then spray the metal components with an anticorrosion agent

or release agent.

650 AP07_048_1007EN
 Pumpingoperations

6.11 Measures for preserv- When placing stationary concrete pumps in storage for more than
ing the value of sta- four weeks, you must carry out the following measures to preserve
tionary concrete their value. Carry out these measures at least every threemonths. If
pumps placed in stor- required due to the climatic conditions to which the stored machine
age is exposed, you must carry out these measures at shorter intervals.

Checklist for value preservation measures for stationary

concrete pumps placed into storage

Assembly Action
Document the date that the machine is placed in storage and the
Documentation
value preservation measures that are carried out.
Protect the untreated surfaces (control blocks, pins, spring pins,
etc.) with a suitable preserving agent.
General Grease the untreated surfaces of mechanical parts (rollers,
chains, etc.) with Vaseline.
Rectify any corrosion damage.
Disconnect the battery.
See the instructions on how to switch off DEUTZ engines with an
EMR4 electronic engine governor in the section "Switching off the
machine".
Electrical system
Check the battery charge state and charge the battery if necess

ary.
Connect the central control unit (CCU) to a supply voltage at six−
monthly intervals.
Empty the water tank and the water lines. Leave the drainage
openings open.
Water Drain the water box. Leave the drainage openings open. Close
the water box cover.
Drain the high
pressure water pump.
Grease all exposed piston rods with Vaseline.
Concrete pump
Grease the interior surfaces of the delivery cylinder with Vaseline.

AP07_078_1501EN 651
 Pumpingoperations

Assembly Action
Open and lock the hopper flap.
Hopper
pp Close the spray guard.
Spray the hopper area with barrier agent.
Cover any exhaust pipes that exit upwards.
Engine
g Close the fuel tank and the supply line to the engine.
Protect the electronics against moisture/corrosion.
Exhaust After Treatment Fill the DEF container completely.
system (EAT system) Maximum storage duration at −40 °C to 25 °C is four months.

Caution
The instructions in this warning notice apply to DEUTZ motors with
an electronic engine governor (EMR4).
When you switch off the ignition, the control unit of the electronic en
gine governor (EMR4) is still supplied with power for approx.
twominutes. During this run−down time, required data is saved in the
control unit and the DEF lines are emptied (risk of freezing).

You must only disconnect or switch off the battery once the control
unit has completed its run−down time of approx. twominutes. Inter
rupting this rundown time will cause a fault in the control unit.

Putzmeister will not accept warranty claims for engine damage and
operating errors that result from a failure to switch off the engine ac
cording to the instructions.

Note
Refer to the engine manufacturer’s documentation for details about
preserving the engine and the exhaust after treatment system.

652 AP07_078_1501EN
 Glossary

7 Glossary

This chapter illustrates the control system symbols (icons for con

crete pumps) and explains the abbreviations and technical terms
that are used in Putzmeister Operating Instructions.

BP14_001_0501EN 7I
 Glossary

7II BP14_001_0501EN
 Glossary

G–1 Symbols for concrete pumps in accordance with German Mechanical Engineering
Association Standard (VDMA 24119)

G–1.1 General (for key, see page G — 7)

3701 3713 3725 5008 6012 7005

3702 3714 4001 6001 6013 7006

3703 3715 4002 6002 6014 7007

3704 3716 4003 6003 6015 7008

3705 3717 4004 6004 6016 7009

3706 3718 5001 6005 PM6017 7010

3707 3719 5002 6006 PM6018 7011

3708 3720 5003 6007 PM6019 7012

3709 3721 5004 6008 7001 8001

3710 3722 5005 6009 7002 8002

3711 3723 5006 6010 7003 8003

3712 3724 5007 6011 7004 8004

BP14_003_0501EN G1
 Glossary

8005 10005 10017 12001 12013 12025

8006 10006 10018 12002 12014 12026

8007 10007 10019 12003 12015 12027

8008 10008 10020 12004 12016 12028

8009 10009 10021 12005 12017 12029

9001 10010 10022 12006 12018 12030

9002 10011 10023 12007 12019 12031

9003 10012 10024 12008 12020 12032

10001 10013 10025 12009 12021 12033

10002 10014 11001 12010 12022 12034

10003 10015 11002 12011 12023 12035

10004 10016 11003 12012 12024 12036

G2 BP14_003_0501EN
 Glossary

12037 12043 12049 12055 13004 14003

12038 12044 12050 12056 PM13005 15001

12039 12045 12051 12057 PM13006 15002

12040 12046 12052 13001 PM13007 15003

12041 12047 12053 13002 14001

12042 12048 12054 13003 14002

G–1.2 Support (for key, see page G — 10)

2601 2604 2607 2610 2613 2616

2602 2605 2608 2611 2614 2617

2603 2606 2609 2612 2615

BP14_003_0501EN G3
 Glossary

G–1.3 Boom, 2–arm (for key, see page G — 10)

1201 1203 1205 1207 1209 1211

1202 1204 1206 1208 1210

G–1.4 Boom, 3–arm (for key, see page G — 10)

1301 1304 1307 1310 1313 1316

1302 1305 1308 1311 1314

1303 1306 1309 1312 1315

G–1.5 Boom, 4–arm (for key, see page G — 11)

1401 1406 1411 1416 1421 1426

1402 1407 1412 1417 1422 1427

1403 1408 1413 1418 1423

1404 1409 1414 1419 1424

1405 1410 1415 1420 1425

G4 BP14_003_0501EN
 Glossary

G–1.6 Boom, 5–arm (for key, see page G — 12)

1501 1506 1511 1516 1521 1526

1502 1507 1512 1517 1522 1527

1503 1508 1513 1518 1523 1528

1504 1509 1514 1519 1524 1529

1505 1510 1515 1520 1525 1530

G–1.7 Boom, 6–arm (for key, see page G — 12)

PM1601 PM1604 PM1607 PM1610 PM1613 PM1616

PM1602 PM1605 PM1608 PM1611 PM1614

PM1603 PM1606 PM1609 PM1612 PM1615

BP14_003_0501EN G5
 Glossary

G–1.8 Ergonic Boom Control, 3–arm (for key, see page G — 13)

PM1301 PM1303 PM1305 PM1307 PM1309

PM1302 PM1304 PM1306 PM1308

G–1.9 Ergonic Boom Control, 4–arm (for key, see page G — 13)

PM1401 PM1403 PM1405 PM1407 PM1409 PM1412

PM1402 PM1403A PM1406 PM1407A PM1410 PM1413

PM1402A PM1404 PM1406A PM1408 PM1411 PM1414

G–1.10 Ergonic Boom Control, 5–arm (for key, see page G — 14)

PM1501 PM1503 PM1505 PM1507 PM1509 PM1512

PM1502 PM1503A PM1506 PM1507A PM1510 PM1513

PM1502A PM1504 PM1506A PM1508 PM1511 PM1514

G–1.11 Ergonic Boom Control, 6–arm (for key, see page G — 14)

PM1601 PM1603 PM1605 PM1607 PM1609 PM1611

PM1602 PM1604 PM1606 PM1608 PM1610

G6 BP14_003_0501EN
 Glossary

G–2 Key to the symbols for concrete pumps

G–2.1 General
3701 Increase/reduce output using rotarycontroller 5001 Agitator, hopper

3702 Increase/reduce output using toggleswitch 5002 Agitator clockwise rotation

3703 Increase output 5003 Agitator anticlockwise rotation

3704 Reduce output 5004 Hopper empty

3705 Reverse pumping 5005 Hopper full

3706 Pumping On 5006 Agitator cut−out

3707 Pumping Off 5007 Hopper level control

3708 Pumping On−Off 5008 High−pressure agitator

3709 Pumping standby 6001 Hydraulic oil excess temperature

3710 Pumping in general 6002 Radiator

3711 Rotor pump in general 6003 Radiator1

3712 Pump flow meter 6004 Radiator2

3713 Full output 6005 Fill accumulator

3714 Half output 6006 Dump accumulator pressure

3715 High pressure pump 6007 Hydraulic cylinder blockage

3716 Pump control system 6008 High−pressure hydraulic system

3717 Change−over 6009 Insufficient hydraulic fluid

3718 Stroke pulse change−over 6010 Hydraulic fluid

3719 Stroke correction 6011 Air

3720 Change−over delay 6012 High pressure

3721 Screw conveyor1 anticlockwise rotation 6013 Accumulator pressure

3722 Screw conveyor1 clockwise rotation 6014 Filter element

3723 Screw conveyor2 anticlockwise rotation 6015 Rod side

3724 Screw conveyor2 clockwise rotation 6016 Piston side

3725 Screw conveyor PM6017 Hydraulic fluid filter water level STOP

4001 Centralised grease lubrication, manual PM6018 Hydraulic fluid filter water level warning

4002 Centralised grease lubrication, automatic PM6019 Hydraulic fluid filter contamination warning

4003 Centralised oil lubrication, manual 7001 Working light

4004 Centralised oil lubrication, automatic 7002 Lighting

BP14_004_0905EN G7
 Glossary

7003 Control cabinet lighting 10010 Speed sensor

7004 Toolbox lighting 10011 Increase speed

7005 Rear light 10012 Reduce speed

7006 Spirit level lighting 10013 Engine air filter

7007 Flashing beacon 10014 Electric motor in general

7008 Acknowledge flashing beacon 10015 Silent

7009 Brake light 10016 Reduced fuel consumption

7010 Side marker lamps container 10017 Tank monitoring

7011 Lighting mast 10018 Coolant level

7012 Diagnostics lamp 10019 Diesel engine control

8001 Machine diagnostics connector 10020 Starter

8002 Read−out data 10021 Manual throttle lever

8003 Read−in data 10022 Start−up relief (soft start)

8004 Read−in minimum value 10023 Diesel supply On

8005 Reset memory contents (save) 10024 Fuel

8006 Cancel memory contents (clear) 10025 Fuel filter draining

8007 Start 11001 Radio remote control

8008 Read−in maximum value 11002 Remote control in general

8009 Menu 11003 Plug in remote control

9001 Control cabinet 12001 Horn

9002 Diagnostics socket 12002 Fault in general

9003 Teleservice 12003 Acknowledge

10001 Diesel engine On 12004 Battery

10002 Diesel engine Off 12005 Battery charging device

10003 Engine oil excess temperature 12006 EMERGENCY STOP activated

10004 Cooling water excess temperature 12007 Acknowledge EMERGENCY STOP

10005 Acknowledge cooling water excess temperature 12008 Stop

10006 Engine oil pressure 12009 Test operation

10007 V−belt failure 12010 Vibrator On

10008 Increase speed, reduce speed 12011 Vibrator Off

10009 Speed 12012 Vibrator

G8 BP14_004_0905EN
 Glossary

12013 Potentiometer 12042 Lock

12014 Off−On 12043 2ndlevel

12015 On 12044 Circuit1

12016 Off 12045 Circuit2

12017 Fast (e.g.acceleration) 12046 Circuits1+2

12018 Normal (e.g.acceleration) 12047 High−pressure limit

12019 Compressor 12048 Flap/closure closed

12020 Compressor On−Off 12049 Flap/closure open

12021 Motor vehicle fuse 12050 Generator

12022 Cable drum 12051 Boom on cradle

12023 Operating hours meter 12052 Manual operation

12024 Operating position 12053 Electrical levelling

12025 Electrical power 12054 See Operating Instructions

12026 Automatic/manual 12055 Wear measurement

12027 Automatic operation 12056 Water

12028 Close shut−off device 12057 Overhead roll−and−fold boom

12029 Open shut−off device 13001 Power take−off

12030 Water tank heating 13002 Truck in general

12031 Cleaning 13003 Plan view

12032 Levelling control in general 13004 Brake in general

12033 Excess pressure PM13005 Driving

12034 Fuse test PM13006 Lifting axle raised

12035 Timer relay PM13007 Lifting axle not raised

12036 Right side 14001 Mixer in general

12037 Left side 14002 Drain mixer

12038 Concrete brake 14003 Activate mixer

12039 Buzzer 15001 Water glass dosing pump

12040 Container 15002 Flushing water pump

12041 Position at the machine 15003 High−pressure water pump

BP14_004_0905EN G9
 Glossary

G–2.2 Support
2601 Support leg/foot retract/extend 2610 Support leg working light

2602 Extend support leg 2611 Support leg retract/extend

2603 Retract support leg 2612 Support foot retract/extend

2604 Lower support foot 2613 Side marker lamps support leg

2605 Raise support foot 2614 Working range on the right

2606 Swing out right support leg 2615 Working range on the left

2607 Swing in right support leg 2616 Enable stability monitoring

2608 Swing out left support leg 2617 Stability monitoring

2609 Swing in left support leg

G–2.3 Boom, 2–arm

1201 Boom in general 1207 Slew boom to the left

1202 Arm 1 up 1208 Slew boom to the right

1203 Arm 1 down 1209 Move arms

1204 Arm 2 up 1210 Move arms switched off

1205 Arm 2 down 1211 Slewing gear activated

1206 Boom activated

G–2.4 Boom, 3–arm

1301 Boom in general 1309 Slew boom to the left

1302 Arm 1 up 1310 Slew boom to the right

1303 Arm 1 down 1311 Move arms

1304 Arm 2 up 1312 Move arms switched off

1305 Arm 2 down 1313 Slewing gear activated

1306 Arm 3 up 1314 Slew boom to the right switched off

1307 Arm 3 down 1315 Slew boom to the left switched off

1308 Boom activated 1316 Arm1 down switched off

G10 BP14_004_0905EN
 Glossary

G–2.5 Boom, 4–arm

1401 Boom in general 1415 Slewing gear activated

1402 Arm 1 up 1416 Arms up switched off

1403 Arm 1 down 1417 Slew boom to the left switched off

1404 Arm 2 up 1418 Slew boom to the right switched off

1405 Arm 2 down 1419 Arm1 down switched off

1406 Arm 3 up 1420 Arms up switched on

1407 Arm 3 down 1421 Tilt switch, arm1 circuit1

1408 Arm 4 up 1422 Tilt switch, arm1 circuit2

1409 Arm 4 down 1423 Tilt switch, arm2 circuit1

1410 Boom activated 1424 Tilt switch, arm2 circuit2

1411 Slew boom to the left 1425 Pressure switch, arm1 circuit1

1412 Slew boom to the right 1426 Pressure switch, arm1 circuit2

1413 Move arms 1427 Unfolding position

1414 Move arms switched off

BP14_004_0905EN G11
 Glossary

G–2.6 Boom, 5–arm

1501 Boom in general 1516 Move arms

1502 Arm 1 up 1517 Move arms switched off

1503 Arm 1 down 1518 Slew boom to the left switched off

1504 Arm 2 up 1519 Slew boom to the right switched off

1505 Arm 2 down 1520 Arm1 down switched off

1506 Arm 3 up 1521 Arms up switched on

1507 Arm 3 down 1522 Tilt switch, arm1 circuit1

1508 Arm 4 up 1523 Tilt switch, arm1 circuit2

1509 Arm 4 down 1524 Tilt switch, arm2 circuit1

1510 Arm 5 up 1525 Tilt switch, arm2 circuit2

1511 Arm 5 down 1526 Pressure switch, arm1 circuit1

1512 Boom activated 1527 Pressure switch, arm1 circuit2

1513 Slew boom to the left 1528 Unfolding position

1514 Slew boom to the right 1529 Arm5 switched on

1515 Slewing gear activated 1530 Arm5 switched off

G–2.7 Boom, 6–arm

PM1601 Boom in general PM1609 Arm 4 down

PM1602 Arm 1 up PM1610 Arm 5 up

PM1603 Arm 1 down PM1611 Arm 5 down

PM1604 Arm 2 up PM1612 Arm 6 up

PM1605 Arm 2 down PM1613 Arm 6 down

PM1606 Arm 3 up PM1614 Boom activated

PM1607 Arm 3 down PM1615 Slew boom to the left

PM1608 Arm 4 up PM1616 Slew boom to the right

G12 BP14_004_0905EN
 Glossary

G–2.8 Ergonic Boom Control, 3–arm

PM1301 Move end hose PM1306 Unfold the placing boom

PM1302 End hose forwards PM1307 Fold the placing boom

PM1303 End hose back PM1608 End hose to the left

PM1304 End hose up PM1309 End hose to the right

PM1305 End hose down

G–2.9 Ergonic Boom Control, 4–arm

PM1401 Move end hose PM1407 Fold the placing boom

PM1402 End hose forwards PM1407A Fold the placing boom (USA)

PM1402A End hose forwards (USA) PM1408 End hose to the left

PM1403 End hose back PM1409 End hose to the right

PM1403A End hose back (USA) PM1410 Upper limit

PM1404 End hose up PM1411 Lower limit

PM1405 End hose down PM1412 Preferred position for arm 1

PM1406 Unfold the placing boom PM1413 Preferred position for arm 4

PM1406A Unfold the placing boom (USA) PM1414 Preferred position arm1 + arm4

BP14_004_0905EN G13
 Glossary

G–2.10 Ergonic Boom Control, 5–arm

PM1501 Move end hose PM1507 Fold the placing boom

PM1502 End hose forwards PM1507A Fold the placing boom (USA)

PM1502A End hose forwards (USA) PM1508 End hose to the left

PM1503 End hose back PM1509 End hose to the right

PM1503A End hose back (USA) PM1510 Upper limit

PM1504 End hose up PM1511 Lower limit

PM1505 End hose down PM1512 Preferred position for arm 1

PM1506 Unfold the placing boom PM1513 Preferred position for arm 5

PM1506A Unfold the placing boom (USA) PM1514 Preferred position arm1 + arm5

G–2.11 Ergonic Boom Control, 6–arm

PM1601 Move end hose PM1607 Fold the placing boom

PM1602 End hose forwards PM1608 End hose to the left

PM1603 End hose back PM1609 End hose to the right

PM1604 End hose up PM1610 End hose back

PM1605 End hose down PM1611 End hose forwards

PM1606 Unfold the placing boom

G14 BP14_004_0905EN
 Glossary

G–3 Abbreviations and technical terms

ADR Arbeitsdrehzahlregelung → Speed of rotation regulation

Agitator safety cutout The agitator safety cutout automatically cuts power to the agitator
and the concrete pump when the grille is opened.

APP → Automatic Piston Pull

Arc configuration Variant of boom movement in Ergonic Boom Control mode on

machines with a Z fold system: the position of the arm assembly
resembles an arc.

Automatic Piston Pull A ball cock is fitted in the drive cylinder. When the ball cock is
closed, you can pull the delivery piston out of the delivery cylinder
to replace it.

Blockage Blockage in the delivery line: the concrete behind the blockage
cannot continue to flow. The blockage may occur due to wedging
caused by coarse particles, etc.

Change−over Reversal of direction of the delivery piston in the middle of a stroke

movement: The → transfer tube switches over. The concrete is still
pumped without interruption.

Change−over delay throttle The change−over delay throttle is a hydraulic component which
delays the change−over of the → transfer tube.

Check book The check book is part of the documentation accompanying the
machine: checklist with confirmation of the legally required checks
for concrete pumps and placing booms

Corner bearing load The corner bearing load is the force transferred to the ground
through each support foot.

BP14_002_0501EN G15
 Glossary

dB Decibels: unit of measurement for the → sound power level

dB (A) Decibels (A): unit of measurement for the → sound pressure level

EBC → Ergonic Boom Control

EDC → Electronic Diesel Control

EGD → Ergonic Graphic Display

EGD−RC → Ergonic Graphic Display  Remote Control

Electronic Diesel Control Automatic vehicle−specific control of fuel consumption

EOC → Ergonic Output Control

EPS → Ergonic Pump System

Ergonicr Registered brand name for all Putzmeister components which

control concrete pumps and placing booms.

Ergonic Boom Control Microprocessor supported system for controlling and regulating
the placing boom. Among other functions, EBC allows you to move
the placing boom using just one joystick.

Ergonic Graphic Display Graphic display in the control cabinet door. The operating state of
the machine is shown in the display. You may also be able to set
functions here, depending on the equipment on your machine.

Ergonic Graphic Display  Graphic display in the remote control. The operating state of the
Remote Control machine is shown in the display. You may also be able to set
functions here, depending on the equipment on your machine.

Ergonic Output Control Microprocessor supported system for economic operation of

theconcrete pump. The minimum engine speed required for
thedelivery rate selected by the operator is automatically set.

Ergonic Pump System Microprocessor supported system for controlling and regulating
the concrete pump. Among other functions, EPS allows you to
restrict the concrete pressure and delivery rate.

G16 BP14_002_0501EN
 Glossary

FFH → Free−Flow Hydraulics

Free−Flow Hydraulics Free−Flow Hydraulics is a type of drive for the concrete pump
which switches the fluid flow from the main pump directly to the
drive cylinders, i.e. there is free fluid flow without interposed
valves.

Fully hydraulic control Fully hydraulic control is a type of control of the concrete pump
which switches the fluid flow from the main pump to the drive
cylinder using valves (closed hydraulic circuit).

Functional fluids Hydraulic fluid, fuel, brake fluid, battery acid etc.

Grille The grille is the protective cover for the hopper and has two
functions:
− Allowing only particles up to a certain size to pass
− Protecting persons against reaching into the hopper

KEP Kolben−Endlagen−Positionierung → Piston end−of−travel

positioning

Lela → Levelled last arm

Level control Level control controls the amount of concrete in the hopper during
pumping operations using a fill−level sensor.

Levelled last arm Last arm of the placing boom in a horizontal position

BP14_002_0501EN G17
 Glossary

Machine card The machine card is part of the documentation accompanying

themachine:
− List of machine components
− Circuit diagram information

Maintenance card A maintenance card describes measures and their sequence for
maintaining the machine and for replacing parts and wear parts.

Monoblock The monoblock is a hydraulic safety valve on the boom hydraulic

cylinders.

NA / NMV NA and NMV are types of power take−off:

− The NA power take−off is a transmission−dependent PTO.
− The NMV power take−off is independent of the clutch.

One−Side−Support One−Side−Support is a type of support for supporting the machine

in narrow spaces.

Operating equipment Battery, filters

OSS → One−Side−Support

PEDOC → Putzmeister Electronic Documentation

Piston end−of−travel positioning A ball valve is fitted in the drive cylinder. When the ball valve is
closed, you can lock the drive cylinder in its end−of−travel position
to replace it.

Piston side

Proportional control Infinitely variable controller for setting the boom speed

Putzmeister Electronic Documentation accompanying the machine on CD−ROM

Documentation

G18 BP14_002_0501EN
 Glossary

Quick disconnect point Arm 1 of the arm assembly can be disconnected at the quick
disconnect point.

Reversal The concrete is sucked back from the delivery line into the hopper.

Rod side

Roll−and−fold system Type of folding of the arm assembly: the arm is rolled when folded
in and out.

Roll configuration Position of the M 31 arm assembly in Ergonic Boom Control

operation when the end hose is moved within the stored limits.

Rotor pump The rotor pump comprises

− a rotor housing
− a rotor (rotating about its central axis)
− two pressure rollers (running freely)
− a pump tube
The pump tube is pressed together as the pressure rollers roll
overit. This pushes the concrete in the pump tube ahead of
thepressure roller towards the rotor housing outlet and into the
delivery line.

RSA Rührwerksicherheitsabschaltung → Agitator safety cutout

BP14_002_0501EN G19
 Glossary

Service operation The Pumping operations − Service operations" toggle switch

onthe control cabinet can be used to switch over between the
concrete pump and the compressor. You can switch on the
compressor, rather than the pump, at the radio remote control if
you set the switch to Compressor".

Snaplock The snaplock is a mechanical safety device to protect against

unintentional extension and retraction of the support legs.

Sound power level The sound power level is a relative measurement used in acous

tics to indicate the noise emissions from a noise source[dB].

Sound pressure level The sound pressure level is a logarithmic measurement for the
relative loudness of the sound [dB(A)].

Speed of rotation regulation The ADR function regulates the mixer drum speed while the truck
is being driven.

Squeeze valve The squeeze valve is a component on the end hose which closes
the delivery line when the pump is stopped.

Stroke correction The stroke is corrected automatically by the addition or removal of

hydraulic fluid through bores in the cylinder. This means that the
delivery piston can achieve its maximum stroke length. Without
stroke correction, the delivery piston would not always reach its
end position.

Support foot The support foot is a component on the end of the support leg.

Support leg The support leg is a telescopic and/or slewable component for
supporting the machine.

Support foot plate The support foot plate is a component on the underside of the
support foot.

G20 BP14_002_0501EN
 Glossary

Teach−in Specialist word for storing in memory

Test reading The test reading is part of the documentation accompanying the
machine: list of machine setting values

to trigger The magnetic switches are triggered, i.e. when an object is

brought near, they switch without any contact being made.

Transfer tube The transfer tube is a component which is swung between the two
delivery cylinders in the hopper. It is the connection between the
delivery cylinder and the delivery line.

UVD Umsteuer−Verzögerungsdrossel → Change−over delay throttle

VHS Vollhydraulische Steuerung → Fully hydraulic control

Z fold system Type of folding of the arm assembly: the arm assembly resembles
the letter Z when folded in and out.

Z configuration Variant of boom movement in Ergonic Boom Control mode on

machines with a Z fold system: the position of the arm assembly
resembles the letter Z.

BP14_002_0501EN G21
 Glossary

G22 BP14_002_0501EN
 Indexofkeywords

8 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.

8—I
 Indexofkeywords

8 — II
 Indexofkeywords

F 8, 5
4
Hydraulic, 3
99

A
F25, 5
4
Hydraulic fluid radiator, 3
106
Abbreviations, G
15
F80, 5
5
Magnetic switches distributor casing,

Static base structure, 3
11, 5
7 3
95
Accessories and attachments, 2
15

Transport, 5
4
Pump control system, 3
101
Accumulator, 3
101
Checks Control panel, With centralized lubri-
Accumulator dump valve, 3
101
Function checks, 4
10 cation system, 3
57
After Sales Service personnel, Defini-
Visual checks, 4
1 Cooling, 6
21
tion of terms, 2
3
Cleaning, 2
48, 6
27 Copyright, 1
2
Agitator, 4
19
Catch basket, 6
31 Corner bearing load, 2
30

Emergency operation, 3
102
Cleaning agents, 2
49

Function description, 3
15 Crawler track, 3
11, 5
7

Compressed air, 2
50
Agitator hopper, Filling, 6
11
Compressed air cleaning, 6
29
Agitator safety cutout, 3
93
Concrete leavings, 6
28

Delivery line, 6
36
D

Acknowledge, 4
15

High−pressure water cleaning, 6
40 Danger zone, 2
4, 2
7

Inspection, 4
13

Hopper, delivery cylinder and S trans

Delivery line systems, 2
8

Unexpected restart, 4
15
fer tube, 6
43
End hose, 2
8, 2
38
Approach route
Mark the water hose, 6
35
Hopper, 2
8

For the machine, 5
11
Post−cleaning procedure, 2
51, 6
49
Machine, 2
8

For truck mixers, 5
11
Preparations, 6
30
Placing boom, 2
7

Minimum clearance from pits, 5
13
Sponge ball, 6
30
Stationary delivery line, 5
19
Arm assembly, Definition of terms,
Suction cleaning, 6
38
Support legs and support feet, 2
7
2
1
T−delivery pipe with wash−out port, DEF container, Filling, 6
6
Assembly, Stationary delivery line, 6
33
Definition of terms
5
18
Wash−out adaptors, 6
32

After Sales Service personnel, 2
3
Auxiliary personnel, Definition of
With auxiliary pump, 6
41

Arm assembly, 2
1
terms, 2
2 Cleaning agents, 2
49
Auxiliary personnel, 2
2
Clearances
Base structure, 2
1
B
From high
voltage lines, 2
22

To delivery lines, 2
43

Concrete pump, 2
1

Danger zone, 2
4, 2
7
Base structure, Definition of terms, Cold weather, 2
40
Delivery line systems, 2
2
2
1
End hose, 2
2
Components
Blockages, 2
42, 6
18
Other, 3
105

Hoseman, 2
2

Machine, 2
1
Breaks in pumping, 6
19
Overview, 3
1

Machine operator, 2
2
Compressed air cleaning, 2
50, 6
29
Maintenance, 2
3
C Concrete leavings, 6
28
Manufacturer, 2
2
Concrete properties, 6
10
Operator, 2
2
Cable remote control, 3
87
Place of work, 2
4, 2
6
Concrete pump, Definition of terms,
Catch basket, 6
31 2
1
Placing boom, 2
1
Centralized lubrication system, 3
57
Qualified personnel, 2
3
Condensate water, 4
3

Description of the functions, 3
19
Signaller, 2
2
Control cabinet
Subject expert, 2
3

Dry running cut
out, 3
21

Central module control cabinet, 3
23
Truck mixer, 2
2

Technical data, 3
57

Ergonic Graphic Display, 3
29
Truck mixer driver, 2
3
Change-over, Description of the func-
tions, 3
13 Control devices
Working area, 2
4, 2
6

Accumulator dump valve, 3
101 Delivery line, Cleaning, 6
36
Changes to the machine, 2
15

Agitator valve, 3
102
Delivery line systems, 2
41
Chassis
Cable remote control, 3
87

Clearance to delivery lines, 2
43

Crawler track, 5
7
Central module control cabinet, 3
23

Continuation delivery lines, 2
44

Description of the functions, 3
10
Electrical, 3
22

Danger zone, 2
8

i
 Indexofkeywords

Definition of terms, 2
2
Conveying, 3
54 Electromagnetic compatibility, 3
6

Fastening delivery lines, 2
43
Coolant level, 3
69 Electrostatic charging, 2
25

Leak tightness and blockages, 2
42
Deactivate EMERGENCY STOP, 3
51
EMC, 3
6

Opening the delivery line, 2
43
EMERGENCY STOP, 3
39, 3
51

Securing delivery lines, 2
41
Engine oil pressure, 3
69 Emergency operation, Agitator, 3
102

Shutting−off, diverting, cleaning, 2
44
Engine oil temperature, 3
69 EMERGENCY STOP button, 2
37,

Suitable delivery line, 2
41
Engine speed, 3
43 3
87, 3
91, 4
12
Delivery rate, Ergonic Output Control,
Engine status, 3
39, 3
68 EMERGENCY STOP function, 4
12
3
73
Ergonic Output Control, 3
53
End hose, 2
38

Fill level of the DEF container (green) ,
Description of the functions, 3
10
Danger zone, 2
8, 2
38
3
40, 3
81

Centralized lubrication system, 3
19
Definition of terms, 2
2

Fill level of the DEF container (orange),

Change
over, 3
13
Ergonomically, 2
39
3
40, 3
68, 3
81

Chassis, 3
10
Extending, 2
13

Fill level of the DEF container (red),

Pump, 3
12 3
40, 3
81
Impermissible end hose, 2
13

Pumping, 3
13
Fill level of the DEF container (yellow), Engine, Possible faults, 4
27

Reverse pumping, 3
13 3
40, 3
81 EOC, Ergonic Output Control, 3
73

S transfer tube, 3
13
Fuel filter, 3
69

Support legs, 3
11 Ergonic Graphic Display, 3
29

High pressure, 3
45

Water box, 3
13
Engine diagnosis, 3
65

Hydraulic fluid overheating, 3
44

Fault memory, 3
70
Designated use, 2
9
Hydraulic fluid radiator, 3
39, 3
54

HOME, 3
35

Inspection intervals, 2
11
Magnetic switch, 3
43

Info, 3
72

Retesting (safety inspection), 2
10
Menu−independent warnings, 3
77

Menu structure, 3
32
Diesel engine, 6
20
Output current monitoring, 3
45

Menu−independent warnings, 3
77

Switching on, 4
7
Pump centralized lubrication system,

Operating elements, 3
30
3
39, 3
45
Diesel Oxidisation Catalyst/Diesel
Pump flow meter, 3
59

Push Over, 3
53
Particle Filter (DOC/DPF) module,
Pump settings, 3
47

SBU switching between rod side and
3
114
Pump status, 3
41
piston side feed, 3
54
Discharge voltage pattern, 2
22
Stroke counter, 3
53
Service, 3
71
Downpipe, 5
25
Tank reserve, 3
39, 3
69
Test screen, 3
34

DPF regeneration strategy, 3
116
Transfer tube, 3
43 Ergonic Output Control, 3
73

Drills, Connecting, 2
39

Warning, 3
39 Exhaust after treatment system,

Warning symbol for DEF quality and 3
110, 6
22
Driving, 2
33 exhaust gas treatment (orange), 3
83
Extensions, End hose and placing

Before moving off, 5
6
Warning symbol for DEF quality and boom, 2
13

During the journey, 5
7 exhaust gas treatment (red), 3
83

Hand signals, 5
5, 5
8
Warning symbol for DEF quality and
Dry running cut-out, Centralized lubri- exhaust gas treatment (yellow), 3
83 F
cation system, 3
21
Warning symbol for engine oil change
required (yellow), 3
85 F 8 chassis, 5
4

Warning symbol: DPF regeneration F 25 chassis, 5
4
E (orange), 3
79
F 80 chassis, 5
5

Warning symbol: DPF regeneration
Earthing, 2
25 (red), 3
79 Face mask, 2
20
Earthing on construction sites with
Warning symbol: DPF regeneration Fastening, Stationary delivery line,
special equipment, 2
25 (yellow), 3
79 5
22
EGD, see Ergonic Graphic Display,
Warning symbol: DPF regeneration Fill level of the delivery cylinders, Cal-
3
29 complete (green), 3
79 culation example, 3
64

Warning symbol: DPF regeneration
EGD symbols Filling with fuel, Machine, 6
5
running (yellow), 3
79

Agitator safety cutout, 3
39, 3
51 Filter

Warning triangle, orange, 3
78

Battery charging control, 3
69
Pressure filter, 4
18

Warning triangle, red, 3
78

Cause of pump stoppage, 3
44
Suction filter, 4
17

Warning triangle, yellow, 3
78

Centralized lubrication system, 3
52

ii
 Indexofkeywords

Filter condition, 4
17 Hydraulic system, 4
1
Responsibility of the machine operator,

Pressure filter, 3
103 2
16

Suction filter, 3
103 Magnetic switches, 3
95
Flash over, 2
24
I
Connector with LEDs, 3
97
Flushing water pump, 3
107, 4
21, Icons, 1
3
Function check, 4
10
5
29 Impermissible end hose, 2
13 Magnetic switches distributor casing,
Function checks, 4
10 3
95
Impermissible working area, 2
6,

Agitator, 4
19 2
14 Maintenance, Definition of terms, 2
3

Agitator safety cutout, 4
13 Improper use, 2
12 Manufacturer, Definition of terms, 2
2

EMERGENCY STOP function, 4
12
Accessories and attachments, 2
15 Menu, Menu–independent warnings,

Filter condition, 4
17
Changes to the machine, 2
15 3
77

Flushing water pump, 4
21
Climbing the placing boom, 2
14 Minimum clearance from pits, 5
13

Gate valve, 4
20
Exclusion of liability, 2
15

Magnetic switches, 4
10 Mobile machines, 2
28

Extending the reach, 2
12

Pump, 4
10
Set
up site, 2
28

Extensions, 2
13

Vibrator, 4
23
Supporting ground, 2
29

High
pressure delivery, 2
15
Function description, Agitator, 3
15
Impermissible end hose, 2
13 Module control cabinet, 3
23

Impermissible working area, 2
14 Monitoring, 6
15

Lifting loads, 2
12
G
Removing obstacles, 2
12
Gate valve, 4
20
Transporting goods, 2
12 O
General conditions Inspection intervals, 2
11 Operating Instructions, 2
17

For using a concrete pump, 3
16 Instructions for laying the line, Statio- Operating panel, 3
89

Height of job, 3
17 nary delivery line, 5
20
Operating procedures, 2
17, 2
18

Operating temperature, 3
18
Operating temperature, 3
18

Service life, 3
16

Site of use, 3
17 L Operator, Definition of terms, 2
2
Liability, Exclusion, 2
15 Overheating, 6
20
Overriding sensors, 3
46
H Lifting eyes, 5
2, 5
3
Lifting loads, 2
12, 2
27 Overview, Components, 3
1
Hand signals

Driving, 5
5, 5
8 Lifting points, 2
35

Pumping operations, 6
3 Loading, 2
27, 2
35, 5
1 P
Hearing protectors, 2
19
Lifting points, 2
35
Parts in contact with concrete, 4
5
Height of job, 3
17 Lubrication, Centralized lubrication
system, 3
19 Personal protective equipment, 2
19
High–pressure water cleaning, 6
40 Personnel, 2
15
Lubrication points, 4
3
High–voltage lines, 2
22
Qualifications, 2
16

Clearances, 2
22
Requirements, 2
16

High
voltage warning device, 2
24 M
Responsibility of the machine operator,

Procedure in the event of a flash over, 2
16
2
24 Machine
Place of work, 2
4, 2
6

Danger zone, 2
8
High-pressure delivery, 2
15
Place of work  hoseman, 2
6

Definition of terms, 2
1
High-voltage warning device, 2
24
Moving machine components, 2
46

Place of work  machine operator, 2
6

Place of work  truck mixer driver, 2
6
Hopper
Observing, 2
47

Pumping operations, 2
45

Cleaning, 6
43
Setting up, 5
14

Danger zone, 2
8
Switching off, 4
24 Placing boom, 2
36, 2
40

Switching on, 4
7
Climbing, 2
14
Hoseman, Definition of terms, 2
2

Danger zone, 2
7
Hydraulic fluid, Radiator, 3
106 Machine operator

Definition of terms, 2
1

Definition of terms, 2
2
Hydraulic fluid radiator, 3
106, 4
3
Extending, 2
13

iii
 Indexofkeywords

Procedure in storms, 2
40 Sound pressure level, 3
8

Unfolding, 2
36
R Space requirement, For truck mixers,

Wind speeds, 2
40 Rating plate, Machine, 3
7 5
11
Preparations for cleaning, 6
30 Reaches, Extending, 2
12 Starting pumping, 6
13
Preserving the value of stationary Ready for operation Static base structure, 3
11, 5
7
concrete pumps placed in storage,
Checking, 2
21 Stationary delivery line, 5
18
6
51
Rendering the machine ready, 2
21
Danger zone, 5
19
Pressure filter, 3
103 Regulations, 2
17, 2
18
Downpipe, 5
25
Pressure gauge, 3
103 Remote control, 2
45, 6
2
Fastening, 5
22
Protective equipment, 2
19
Cable remote control, 3
87
Fixed point, 5
23

Face mask and respiratory protector,
Horizontal, 5
22
Removing obstacles, 2
12
2
20
Instructions for laying the line, 5
20

Hearing protectors, 2
19 Respiratory protection, 2
20
Riser, 5
25

Protective gloves, 2
20 Responsibility of the machine opera-
SK delivery line system, 5
26

Protective goggles, 2
20 tor, 2
16
Vertical and inclined, 5
24

Safety footwear, 2
19 Restrictions, Cold weather, 2
40 Stationary machines, 2
26

Safety harness, 2
20 Retesting (safety inspection), 2
10
Lifting machines, 2
27

Safety helmet, 2
19
Loading, 2
27
Reverse pumping, Description of the
Protective gloves, 2
20 functions, 3
13
Set
up site, 2
26
Protective goggles, 2
20
Stationary placing booms, 2
26
Riser, 5
25

Transporting, 2
27
Pump, Description of the functions, Rod side – piston side feed, 5
27
3
12 Stationary placing booms, 2
26

Pump control system, 3
101 Stop plates, Water box, 6
12

Pump flow meter, 3
59

S Storm, 2
40

Pump functions S transfer tube, Description of the Subject expert, Definition of terms,

Stroke length, 4
11 functions, 3
13 2
3

Stroke time, 4
11 Safety equipment, 3
3 Suction cleaning, 6
38
Pumping operations, 2
45 Safety footwear, 2
19 Suction filter, 3
103

Blockages, 6
18 Safety harness, 2
20 Support legs, Description of the func-

Breaks in pumping, 6
19 tions, 3
11
Safety helmet, 2
19

Concrete properties, 6
10 Support legs and support feet, Dan-

Cooling, 6
21 Selective Catalytic Reduction (SCR),
ger zone, 2
7

Damping valve, 6
17 3
112
Supporting ground, 2
29, 5
12

Diesel engine, 6
20 Service life, 3
16

Corner bearing loads, 2
30

Exhaust after treatment system, 6
22 Set-up site, 2
26, 2
28, 5
10

Filling the agitator hopper, 6
11 Supports, 2
31

Accessibility, 5
11

Hand signals, 6
3
Approach route, 5
11 Switches off the pump, 4
24

Monitoring, 6
15
Approach route for truck mixers, 5
11 Switching between rod side and

Overheating, 6
20
High−voltage lines, 2
22 piston side feed, 3
55

Preconditions, 6
1
Minimum clearance from pits, 5
13 Symbols, 1
3

Pumping, 6
14
Space for truck mixers, 5
11

Safety, 2
45 Symbols for the control system, G
1

Supporting ground, 5
12

Saturated mix, 6
10
Supports, 2
31

Starting pumping, 6
13
Setting up, Machine, 5
14 T
Shutting down the motor, 4
24 T–delivery pipe with wash–out port,
Q Signaller, Definition of terms, 2
2 6
33
Qualifications, 2
16 Site of use, 3
17 Technical data, 3
5
SK delivery line system, 5
26
Centralized lubrication system, 3
57
Qualified personnel, Definition of
terms, 2
3
Sound power level, 3
8
Sound power level, 3
8

iv
 Indexofkeywords

Sound pressure level, 3
8 Warning triangle, red, Power reduc-

Technical terms, G
15 tion stage 2, 3
78

Temperatures, 3
18 Warnings, Menu–independent, 3
77

Restrictions, 2
40 Wash–out adaptors, 6
32
Test run, 4
6 Water, 2
51

Diesel engine, 4
7 Water box, 4
4

Machine, 4
7
Description of the functions, 3
13
Towing, 2
34
Stop plates, 6
12
Transfer tube, Damping valve, 3
14, Water hose, Marking, 6
35
6
17 Water pump, 3
107
Transfer tube damping, 6
17 Water pump lever, 3
100
Transfer tube damping cock, 3
101 Wind speeds, 2
40
Transfer tube damping valve, 3
14, Working area, 2
4, 2
6
6
17
Impermissible working area, 2
5, 2
6,
Transport, 5
1 2
14

Chassis, 5
4
Permitted working area, 2
5

Crawler track, 5
7 Working with the machine

Driving with an F 8 chassis, 5
4
Before working with the machine, 2
21

Driving with an F25 chassis, 5
4
Checking that the machine is ready for

Driving with an F80 chassis, 5
5 operation, 2
21

Loading, 5
1
Rendering the machine ready for ope

Transporting, 2
27 ration, 2
21
Transporting goods, 2
12
Truck mixer, 2
47

Definition of terms, 2
2
Truck mixer driver, 2
47

Definition of terms, 2
3

U
Unexpected restart, Agitator safety
cutout, 4
15

V
Vibrator, 3
109, 4
23
Visual checks, 4
1

Condensate water, 4
3

Functional fluids, 4
2

Hydraulic fluid radiator, 4
3

Hydraulic system, 4
1

Lubrication points, 4
3

Parts in contact with concrete, 4
5

Water box, 4
4

W
Warning triangle, orange, Power re-
duction stage 1, 3
78

v
Service Instructions
for machine operator and maintenance staff
always keep by the machine

Translation of the original Operating Instructions

Stationary
concrete pump BSA 1409 D4

Machine no. 210110932

19−03−04

The paper on which this document is printed is 100% chlorine free E Putzmeister Concrete Pumps GmbH 1994
Putzmeister Worldwide

Deutsch
Putzmeister Concrete Pumps GmbH +49−7127−599−0 pmw@pmw.de

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

España Putzmeister Ibérica S.A. +34−91−428 81 00 recepcion@putzmeister.es

PME Camino de Hormigueras 173
Pol. Ind. Vallecas +34−91−428 81 43 www.putzmeister.es
E− 28031 Madrid
France Putzmeister France +33−164 64 39 39 Infopmf@putzmeister.fr
PMF 3, rue Paul Henri Spaak
ZAE Jean Monnet +33−164 64 39 29 www.putzmeister.fr
77240 Vert Saint Denis
Great Putzmeister Limited +44−1246−2642 00 info@putzmeister.co.uk
Britain Carrwood Road
PMUK GB−Chesterfield +44−1246−26 00 77 www.putzmeister.co.uk
Derbyshire S41 9QB
Türkiye Putzmeister Makine Sanayi ve Tic. A.ƞ +90−282−735−1000 pm@putzmeister.com.tr
PTR G.O.PaƟa Mah.
Naműk Kemal Bulvarű No: 6 +90−282−738−1001 www.putzmeister.com.tr
59500 Çerkezköy / TEKŰRDA

USA Putzmeister America +1−262−886−3200 pmr@putzam.com
PMA 1733 90th Street
Sturtevant, WI 53177 USA +1−262−886−3212 www.putzmeister.com

South Putzmeister S.A. (Pty) Ltd. +27−11−794−37 90 pmsa@icon.co.za

Africa Cnr. Bramm & Citrus St. Honeydew
PMSA P.O.Box 5146 ZA 2118 Cresta +27−11−794−41 19 www.putzmeister.co.za
South Africa
India Putzmeister Concrete Machines Pvt Ltd +918326696000 info@pmw.co.in
PCM Plot No. N4, Phase IV
Verna Industrial Estate, Verna Salcete +91832−6696300 www.pmw.co.in
Goa−403722

Japan Putzmeister Japan Co. Ltd. +81−476−36−8907 info@putzmeister.jp

PMJ
7−4 Misawa, Tomisato−shi +81−476−36−8908 www.putzmeister.jp
Chiba 286−0225, Japan
Korea Putzmeister Korea Co. Ltd. +82−31−433−4541 putzmstr@chollian.net
PMK 59 Huimanggongwon−ro, Chungwang−Dong
Shihwa Ind. complex 2 MA 707−1 HO +82−31−498−7230 www.putzmeister.co.Kr
Shihung−city, Kyonggi−Do, Korea
Russ
OOO Putzmeister−Rus +7−495−775−22−37 info@putzmeister.ru
land Urgumskaja Straße 4, Geb. 31
PMR 129343 Moskau, Russia +7−495−775−22−34 www.putzmeister.ru
 de Übersetzung der Originalbetriebsanleitung
bg Ïðåâîä íà îðèãèíàëíî Ðúêîâîäñòâî çà ðàáîòà
cs Pƙeklad originálního návodu k obsluze
da Oversættelse af den originale driftsvejledning
el MetÜfrash tou prwtotýpou twn odhgiþn leitourgßaj
en Translation of the original Operating Instructions
es Traducción de las instrucciones de servicio originales
et Algupärase kasutusjuhendi tõlge
fi Alkuperäisen käyttöohjeen käännös
fr Traduction des instructions de service originales
hr Prijevod izvornika naputka za uporabu
hu Eredeti üzemeltetési útmutató fordítása
it Traduzione delle istruzioni d’uso originali
lt Eksploatavimo instrukcijos originalo vertimas
lv Lietoơanas pamcbas tulkojums no oriinlvalodas
nl Vertaling van de oorspronkelijke gebruiksaanwijzing
no Oversettelse av original brukerhåndbok
pl TƂumaczenie oryginalnej instrukcji eksploatacji
pt Tradução das Instruções de funcionamento originais
ro Traducerea instrucƣiunilor de funcƣionare originale
ru Gthtdjl abhvtzzjuj herjdjlcndf gj ärcgkefnfwbb
sk Preklad originálneho návodu na obsluhu
sl Prevod izvirnih navodil za uporabo
sv Översättning av original instruktionsbok
tr Orijinal kullanűm kűlavuzunun tercümesi

BP00_030_0911EN
BP00_030_0911EN
 Tableofcontents

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

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

2 Safety regulations
2.1 Basic principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 1
2.1.1 Exclusion of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  1

2.2 Requirements for special work . . . . . . . . . . . . . . . . . . . . . . . 2 — 2

2.3 Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 4

2.4 Working on the placing boom . . . . . . . . . . . . . . . . . . . . . . . . 2 — 5

2.5 Safety-relevant components . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 5

2.6 Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 6

2.7 Protective and safety equipment . . . . . . . . . . . . . . . . . . . . . 2 — 6

2.8 Electrical power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 7

2.8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  7
2.8.2 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  8
2.8.3 Power at the construction site . . . . . . . . . . . . . . . . . . . . . . . . . . 2  8

2.9 Hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 9

2.9.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  9
2.9.2 Replacing hydraulic hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  10

2.10 Noise emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 10

2.11 Exhaust fumes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 11

2.12 Functional fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 11

2.13 Disposal of the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 12

210110932 I
 Tableofcontents

3 Safety equipment
3.1 Overview of the safety equipment . . . . . . . . . . . . . . . . . . . . 3 — 1
3.1.1 Active safety functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  1
3.1.2 Passive safety functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  1
3.1.3 Organizational measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  1
3.1.4 Safety−related parts (SRPs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  2
3.1.5 Safety components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  4
3.1.6 Parts with increased maintenance requirements . . . . . . . . . 3  4

3.2 EMERGENCY STOP function . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 5

3.2.1 Description of the functions . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  5
3.2.2 Function check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  6

3.3 Agitator safety cutout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 7

3.3.1 Description of the functions . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  8
3.3.2 Function check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  9
3.3.3 Acknowledging the agitator safety cutout . . . . . . . . . . . . . . . 3  11

3.4 Separating protective devices . . . . . . . . . . . . . . . . . . . . . . . . 3 — 12

3.4.1 Description of the functions . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  12
3.4.2 Function check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  12

3.5 Grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 14
3.5.1 Description ofthefunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  14
3.5.2 Function check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  15

3.6 Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 16
3.6.1 Description ofthefunctions . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  16
3.6.2 Function check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  16

4 Special modes of operation

4.1 Emergency operation – pump function . . . . . . . . . . . . . . . 4 — 1

4.2 Agitator emergency operation . . . . . . . . . . . . . . . . . . . . . . . . 4 — 3

4.3 Recovering the machine after faults occur . . . . . . . . . . . . 4 — 5

4.3.1 Recovery with on
board equipment . . . . . . . . . . . . . . . . . . . . . 4  6

II 210110932
 Tableofcontents

5 Maintenance
5.1 Daily tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 — 1
5.1.1 Daily visual checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  1
5.1.2 Function check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  2
5.1.3 When pumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  3
5.1.4 After every job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  3

5.2 Maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 — 4

5.2.1 As required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  4
5.2.2 Regular maintenance tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  5

5.3 Residual risks during maintenance, inspection

and repair work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 — 7
5.3.1 Personal protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . 5  7
5.3.2 Personnel requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  7
5.3.3 Auxiliary devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  7
5.3.4 Residual risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  8

5.4 General tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 — 10

5.4.1 Set screws and nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  10
5.4.2 Flared screwed joint, reassembly . . . . . . . . . . . . . . . . . . . . . . . 5  11
5.4.3 Profiled ring joint, reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 5  11
5.4.4 WALFORMplus threaded union . . . . . . . . . . . . . . . . . . . . . . . . 5  12
5.4.5 WALFORMplus threaded union, reassembly . . . . . . . . . . . . . 5  13

5.5 Functional fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 — 15

5.5.1 Hydraulic fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  15
5.5.2 Level of contaminant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  17
5.5.3 Lubricant analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  17
5.5.4 Storage of lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  17

5.6 Lubricant recommendation . . . . . . . . . . . . . . . . . . . . . . . . . . 5 — 18

5.6.1 Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  20
5.6.2 Greases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  21
5.6.3 Hydraulic fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  22

210110932 III
 Tableofcontents

Maintenance cards
00−001 Visual checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  25
03−002 Function checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  27
03−026 Checking the accumulator . . . . . . . . . . . . . . . . . . . 5  29
03−010 Changing the hydraulic fluid . . . . . . . . . . . . . . . . . . 5  37
04−002 Hydraulic hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  41
04−005 Vacuum meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  45
04−012 Changing the suction filter element . . . . . . . . . . . . 5  47
04−013 Changing the pressure filter element . . . . . . . . . . 5  53
04−019 DEF delivery pump filter change . . . . . . . . . . . . . . 5  59
06−022 Change of delivery piston with APP . . . . . . . . . . . 5  63
07−069 Replacing the transfer tube bearing . . . . . . . . . . . 5  73
07−070 Replacing the switching shaft bearing
(flanged bearing) . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  79
07−071 Replace the spectacle wear plate . . . . . . . . . . . . . 5  95
07−072 Replacing the Stransfertube . . . . . . . . . . . . . . . . . 5 109
07−073 Replacing the Stransfertube wear sleeve . . . . . 5 117
07−074 Replacing the thrust ring and wear ring . . . . . . . . 5 125
07−075 Adjusting the Stransfertube . . . . . . . . . . . . . . . . . 5 131
08−007 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 145
10−007 Measuring the wall thickness
(Machines with Stransfer tube) . . . . . . . . . . . . . . . 5 147
10−044 Measuring the wall thickness of two−layer pipes 5 153

Index of key words

IV 210110932
 GuidetotheServiceInstructions

1 Guide to the Service Instructions

This chapter contains notes and information that will help you to use
these Service Instructions. Do not hesitate to contact us if you have
any queries:

Putzmeister Concrete Pumps GmbH

After Sales department
Max
Eyth
Str. 10
72631 Aichtal
Telephone: +49 (0) 7127 5990
Fax: +49 (0) 7127 599 520
E
mail: services@pmw.de
or contact the branch or works agency that is responsible for you.

Address:

Telephone:

Fax:

E
mail:

BP01_009_1011EN 1I
 GuidetotheServiceInstructions

1II BP01_009_1011EN
 GuidetotheServiceInstructions

1.1 Foreword The Service Instructions contain important information about the
maintenance of the machine. Observing these instructions helps to
avoid danger, to reduce repair costs and downtimes, and to increase
the reliability and service life of the machine.

The Service Instructions must be supplemented by the relevant

national rules and regulations for accident prevention and environ

mental protection.

The Service Instructions must always be available wherever the ma

chine is in use.

These Service Instructions must be read and applied by any person

in charge of carrying out work with or on the machine, e.g.
− in operation, including setting up, fault rectification in the course of
work, removal of production waste, care and disposal of fuels and
consumables;
− maintenance (servicing, inspection, repair) and/or
− Transport
.

In addition to the Service Instructions and mandatory rules and re

gulations for accident prevention in the country and place of use of
the machine, the generally recognized rules of technology for safe
and proper working must be observed.

BP01_010_1011EN 11
 GuidetotheServiceInstructions

Should you have any questions after studying the Service Instruc

tions, the branch or agency serving you, or the Aichtal Works, will be
happy to provide you with more information.

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

These Service Instructions describe the vehicle superstructure only.

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

In the interests of constant improvement, modifications are made

from time to time and it may be the case that we were unable to take
these into consideration when these Service Instructions were
printed.

In the event of any amendment, the copy of the Service Instructions

that is intended for the machine will be replaced in full.

The reproduction, distribution and utilization of this document as well

as the communication of its contents to others without explicit author

ization is prohibited. Offenders will be held liable for the payment of
damages. All rights reserved in the event of the grant of a patent,
utility model or design.

© Putzmeister Concrete Pumps GmbH 1994

12 BP01_010_1011EN
 GuidetotheServiceInstructions

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

" Task symbol

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

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

See also the maintenance cards:

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

The following special tools are required:

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

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

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

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

BP01_003_0601EN 13
 GuidetotheServiceInstructions

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

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

of the danger precisely.

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

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

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

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

14 BP01_003_0601EN
 GuidetotheServiceInstructions

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

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

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

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

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

BP01_003_0601EN 15
 Safetyregulations

2 Safety regulations

These safety regulations conform to the chapter Maintenance and

special work" in the VDMA brochure

Safety manual Concrete delivery and placing machines".

The safety regulations in the Operating Instructions must also be fol

lowed for all maintenance and special work.

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

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

information:
 EN 12001, Conveying, spraying and placing machines for con
crete and mortar
 EN 12100, Safety of machinery,
 EN 60204−1, Electrical equipment of machines.
 In the Federal Republic of Germany: DGUVRegulation101−012,
Concrete pumps and placing booms.

BP03_083_1701EN 2I
 Safetyregulations

2II BP03_083_1701EN
 Safetyregulations

2.1 Basic principle The safety regulations in the Operating Instructions for this machine
apply whenever the machine is operated.

Danger
There is an increased risk of accidents during a special operation.
You may only carry out the activities described in these service in
structions if:
 you have been trained for these activities by the machine manu
facturer
 you have been authorized for these activities by the machine oper
ating company

2.1.1 Exclusion of liability We state here expressly that Putzmeister accepts no liability for dam

age arising from incorrect or negligent operation, servicing or main

tenance or as a result of use contrary to the designated use. This
statement is particularly valid for modifications to, additions to and
customization of the machine that are liable to compromise safety.
The guarantee will no longer be valid in such cases.

BP03_084_1011EN 21
 Safetyregulations

2.2 Requirements 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
tasks may only be carried out by qualified personnel.

Workshop equipment appropriate to the task in hand is absolutely

necessary for the execution of maintenance work.

If changes have been made to the machine, it must be checked by

a subject expert before recommissioning.

Secure a wide area around the maintenance area as far as is

necessary.

A machine completely shut down for maintenance and repair work

must be secured against being restarted inadvertently:
− Lock the main control devices and remove the key.
− If a main switch is fitted, attach a warning plate to it.

Only carry out maintenance work if the machine is parked on level

and sufficiently supporting ground and is secured to prevent it roll

ing away.

Use specially designed or otherwise suitable climbing aids and

working platforms when carrying out assembly work above head
height. Never use machine parts as climbing aids. Keep all hand

grips, steps, railings, platforms and ladders free from dirt, snow and
ice.

22 BP03_085_1901EN
 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.

Attachment of loads and signalling to crane operators should only

be entrusted to experienced personnel. 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 car

ried out by qualified personnel trained for such work.

Clean any traces of oil, fuel or preservatives from the machine, es

pecially connections and threaded unions, before carrying out
maintenance or repair work. Do not use aggressive cleaning ag

ents. Use lint−free cleaning rags.

Bolted connections that you have loosened for carrying out main

tenance and repair work must always be replaced or retightened in
accordance with manufacturer specifications.

Do not open gas−filled spring elements, as used on maintenance

flaps, for instance. The spring elements are filled with gas under
high pressure which can escape explosively if you attempt to open
them. Relieve the tension on systems under mechanical stress.

Be aware of hot functional fluids and surfaces (hydraulic fluid, hy

draulic fluid radiator, etc.).

Ensure that all functional fluids, consumables and replaced parts

are disposed of safely and with minimum environmental impact.

BP03_085_1901EN 23
 Safetyregulations

2.3 Welding Only carry out welding, flame cutting and grinding operations on
the machine once this has been expressly approved by the manu

facturer.

Only qualified personnel may carry out welding work in line with
manufacturer specifications, especially on the placing boom, on the
supports, on load−bearing parts, on fuel and oil tanks or other com

ponents which are important for industrial safety. This work must be
inspected by qualified welding personnel. The operator must docu

ment the evidence of the formal qualifications of the welder and the
qualified welding personnel.

Always attach the earth cable of the welding unit directly to the
component which is being welded. The welding current must not
flow through hinges, cylinders, etc. Significant damage may be
caused in the event of a flash over.

wz0215

Electronic components can be destroyed by stray voltage during

arc welding processes. For this reason:
− Disconnect the remote control cable from the control console.
− Disconnect all cables leading to the receiver of the radio remote
control system.
− Close connector sockets with caps.
− Disconnect the positive and negative leads from the battery.

Clean the machine and its surroundings of dust and flammable

substances and make sure that the premises are adequately venti

lated before carrying out welding, flame
cutting and grinding oper

ations, otherwise there is a risk of explosion.

24 BP03_085_1901EN
 Safetyregulations

2.4 Working on the plac- Only carry out maintenance and repair work on the placing boom if
ing boom the placing boom is folded or properly supported, the engine is
switched off and the support legs are secured.

Support the placing boom arms before starting work on the valves,
cylinders or hydraulic lines on the boom.

The delivery line was installed without tension with the placing
boom in the driving position and can only be replaced without diffi

culty in this condition. Stresses may be generated on folding if the
delivery line is replaced when the placing boom is unfolded.

Do not remove the entire delivery line but rather replace it bit by bit,
e.g. replace the boom arm with a new boom arm. Otherwise, the
pivot points of the new delivery line will have to be redetermined
using special equipment.

2.5 Safety-relevant com- Work on safety−relevant components requires particular specialist

ponents knowledge.

The following activities in particular must only be carried out by

qualified personnel that have been authorised by the manufacturer:
− Repairing, replacing or adjusting safety−relevant components
and adjustable devices (pressure limiting valves, potentiometers,
fluid flow limiters, hydraulic cylinders, sensors, etc.)
− Removing lead seals

Modifications to the machine data (in particular, increasing pres

sures, modifying speeds, etc.) are not permitted.

BP03_085_1901EN 25
 Safetyregulations

2.6 Software If a machine is equipped with software, the software may only be
used as is provided for in the manufacturer’s Operating Instructions.

Only persons authorized by the manufacturer may intervene in the

machine’s software. This also applies to updates.

Unauthorized interventions in the machine’s software may lead to

severe damage and accidents.

2.7 Protective and safety Any safety equipment 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 com

plete and in a perfectly legible condition.

It is your responsibility as operator to ensure that any warning signs

and information plates that have been damaged or rendered illeg

ible are replaced without delay.

26 BP03_085_1901EN
 Safetyregulations

2.8 Electrical power

2.8.1 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 sec

tion2.8.3,entitled Power at the construction site".

wz0235

Machine components which are to undergo maintenance work must

be de
energized. Ensure that disconnected machine components
cannot be restarted. First of all, you must check that de
energized
parts are indeed de
energized, then earth and short
circuit them
and isolate adjacent live parts.

Disconnect the negative lead from the battery before starting any
work on the electrical system of machines with an internal combus

tion engine. When reconnecting, connect the positive terminal first,
and then the negative terminal.

Before starting work on high
voltage assemblies and after cutting

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

BP03_085_1901EN 27
 Safetyregulations

2.8.2 Electrical components Control cabinet, motor and control elements are protected as stan

dard in accordance with degree of protection IP54. IP54 means:
− Complete protection against contact with live components or in

ternal moving parts. Protection against damaging dust deposits.
− Water spraying on the equipment from random directions must
not have a damaging effect.

Only use original fuses with the specified voltage rating. Bridging or
the use of fuses with too high a rating can irreparably damage the
electrical system. You must switch off the machine immediately if a
fault occurs in the power supply.

2.8.3 Power at the con- The power on the construction site must be supplied from a special
struction site feed point (construction site power distribution point). Machines
with an electric motor must not be connected to the mains power
supply.

Only trained and qualified personnel are permitted to work on elec

trical systems with an operating voltage of more than 25volts alter

nating voltage or 60 volts direct current. Only such qualified per

sonnel 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.

28 BP03_085_1901EN
 Safetyregulations

2.9 Hydraulic systems

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

Always wear your personal protective equipment when carrying out

work on the hydraulic system. Escaping fluid is toxic and can pen

etrate the skin.

wz0245

Injection through the skin is a major medical emergency. In the

event of injuries caused by pressurized fluid, inform the company
medical officer and call a medical specialist immediately. This also
applies for injuries which may seem only slight. Hydraulic fluid
which has penetrated underneath the skin must be removed im

mediately. Otherwise, there is a risk of death due to impaired blood
circulation and infections.

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

draulic, pneumatic and delivery lines) must be depressurized ac

cording to assembly descriptions before repair work is started.

Work only on depressurized systems. Switch the hydraulic pump

drive and the engine off, as there is otherwise a risk of injury
caused by functional fluids escaping under pressure. Where a hy

draulic accumulator is fitted, open the accumulator dump valve to
prevent any movements of the machine as a result of the residual
pressure. Modifications to the hydraulic accumulator are prohibited.

Be aware that enclosed hydraulic fluid can remain under pressure

for a certain length of time. Do not open any hydraulic systems if
they are under load from an external force (particularly from a
raised placing boom).

BP03_085_1901EN 29
 Safetyregulations

Lay and install hydraulic lines in accordance with the current rules
of engineering. Connections must be fitted at the appropriate
points. Fittings and the length and quality of the hoses must comply
with requirements.

You must carefully vent the hydraulic system after any maintenance
work, as there is otherwise a risk of injury caused by swinging and
telescopic support legs extending rapidly, the placing boom lower

ing, etc. Open vent valves very carefully until hydraulic fluid starts
to escape. You should on no account open vent valves further than
necessary or go so far as to remove them.

Damaged hydraulic lines must be replaced rather than repaired.

You must replace damaged or saturated hydraulic hoses immedi

ately. Hydraulic fluid spray escaping under pressure can cause in

juries and fires.

2.9.2 Replacing hydraulic During retesting, hydraulic hoses must be checked by a subject
hoses expert for external damage. The retest must be recorded in the
check book. The operator must have hydraulic hoses replaced if
they show signs of external damage.

2.10 Noise emissions The place of work in normal operation is with the remote control. For
this reason, it is not possible to specify a particular place of work for
the machine operator. Take the values for the sound pressure level
and sound power level from the machine Operating Instructions.

Wear suitable personal protective equipment in the vicinity of the

machine.

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

their personal ear protection. You are responsible for ensuring that
your personnel comply with this regulation.

All soundproofing equipment must be fitted and in perfect condi

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

210 BP03_085_1901EN
 Safetyregulations

2.11 Exhaust fumes Vehicle exhaust gases contain constituents which can be lethal or
carcinogenic. Operate internal combustion engines and fuel−oper

ated heating systems only in adequately ventilated premises. Be

fore starting up the engine in enclosed spaces, make sure that
there is adequate ventilation and direct the exhaust gases away
from the place of work.

Wear personal protective clothing and equipment for all work in

which exhaust gases or particles of building material can enter the
body through the respiratory passages. Comply with the information
issued by the manufacturer of the building material.

2.12 Functional fluids When handling oils, greases and other functional fluids, observe the
safety regulations applicable to the product concerned (see the
safety data sheet).

Oils, fuel and other functional fluids may be hazardous to health

upon contact with the skin, etc. You must, therefore, always wear
personal protective clothing and equipment when you are handling
toxic, caustic or other functional fluids that are hazardous to health
and always take note of the manufacturer’s information.

wz0146

Take care when handling toxic and caustic functional fluids (brake
fluid, battery acid, water glass, concrete set accelerating admix

tures, cement, etc.). Building materials containing cement have a
highly alkaline effect when they react with water (and also with per

spiration). Concrete additives are toxic and caustic.

BP03_085_1901EN 211
 Safetyregulations

Cleaning agents, concrete release agents, preserving agents etc.

propelled by compressed air can cause very serious damage to the
respiratory tract if a respiratory protection mask is not worn. Spray
mist enters the lungs very easily.

Frequent injuries are eye injuries caused by concrete spatter, water

glass or other chemical substances.

Take care when handling hot functional fluids and consumables

(risk of burning or scalding).

Have used operating equipment and functional fluids such as

filters, batteries, oil, brake fluid, etc. disposed of properly. Used
cleaning rags should also be disposed of properly.

wz0186

2.13 Disposal of the ma- To dispose of the machine, you must proceed in accordance with
chine all points in the disposal regulations which apply in your country.
During the disposal operation, you must observe the following in
particular:
− Remove the functional fluids, particularly hydraulic fluids, engine
oils, fuel, brake fluid, concrete admixtures, any environmentally
hazardous functional fluids or functional fluids which are hazard

ous in any other way, and dispose of these correctly.
− Remove the operating equipment, particularly the hydraulic fluid
reservoir, hydraulic cylinder, hydraulic fluid radiator, hydraulic
lines and hoses and other components which may contain resid

ual functional fluids, and dispose of these correctly.
− Remove the steel structure and dispose of it correctly, e.g. by re

cycling.
− Dispose of the truck or the drive unit correctly.

212 BP03_085_1901EN
 Safetyequipment

3 Safety equipment

The safety equipment on the machine is described in this chapter. In

particular, it contains information about
− Intervals for inspection by subject experts
− Intervals for function checks

BP15_001_1202EN 3I
 Safetyequipment

3II BP15_001_1202EN
 Safetyequipment

3.1 Overview of the safety Depending on the type of machine and its equipment, the following
equipment safety equipment may be fitted. Please see the machine card for de

tails about which safety equipment your machine has been fitted
with. Carry out checks on the existing safety equipment according to
the following descriptions within the specified intervals.

3.1.1 Active safety functions

Intervals for inspection by a Interval for function check

subject expert
EMERGENCY STOP function annually Before the machine is used
each time
Agitator safety cutout annually Before the machine is used
each time

3.1.2 Passive safety functions

Intervals for inspection by a Interval for function check

subject expert
Separating protective de
annually each time a separating pro

vices tective device is removed
Grille annually Once a month

3.1.3 Organizational measures

Intervals for inspection by a Interval for function check

subject expert
Plates annually Once a month

AP15_002_1701EN 31
 Safetyequipment

3.1.4 Safety–related parts (SRPs)

Danger
Incorrect assembly of safety−related parts can result in malfunctions.
This creates a risk of death.
Safety−related parts (SRP) should only ever be repaired, maintained
or replaced by qualified personnel with the necessary authorisation.

Safety
related parts (SRP) are components that ensure the safety of

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

Read the EB00−5−xxxxx−xxxx" sheet to ensure that you are aware of

the SRPs fitted on the machine.

SRP marking

AP15_002_1701EN 1

Spare parts sheet Spare part packaging

32 AP15_002_1701EN
 Safetyequipment

1 2 3 4 5

AP15_002_1701EN 2

Pos.0 Illustration Meaning

1 Character: Asterisk *" Item not available for order
Character: Exclamation mark
2 Safety−related part (SRP)
!"
Service life of the SRP [years]
3 Number
e.g. 10" = 10 years
4 Symbol: Hourglass" Service life of the SRP
Example illustration: Spare parts sheet
5 Graphic
EB00−5 XXXXX−XXXX" Safety−related parts

Note
Putzmeister specifies a service life(3) for every safety−related part.
SRPs must be replaced once this service life has elapsed.

AP15_002_1701EN 33
 Safetyequipment

3.1.5 Safety components

The following listed parts are defined as safety components. This in

cludes the following components in particular:
− Pressure limiting valves

Danger
Incorrect assembly of components can result in malfunctions.
This creates a risk of death.
Safety components should only ever be repaired, maintained or re
placed by qualified personnel with the necessary authorisation.

3.1.6 Parts with increased maintenance requirements

The following listed parts are defined as parts with increased main

tenance requirements. This includes the following components in
particular (depending on the machine):
− Accumulator
− Accumulator bladder
− Gas valve insert for accumulator

Danger
Incorrect assembly of parts with increased maintenance require
ments can result in malfunctions.
This creates a risk of death.
Components with increased maintenance requirements should only
ever be repaired, maintained or replaced by qualified personnel with
the necessary authorisation.

34 AP15_002_1701EN
 Safetyequipment

3.2 EMERGENCY STOP function

ISO13849
1:2015 category1 PLc

Intervals for inspection by a
annually
subject expert
Intervals for function checks Before the machine is used each time

3.2.1 Description of the As soon as an EMERGENCY STOP button is pressed, all dangerous
functions machine movements stop. The following actions are triggered when
the relevant components are present on the machine:

Area Safety action

Pump − The agitator stops,

− The change
over valve is de−energized,
− The accumulator dump valve is opened and the
accumulator (if fitted) is emptied,
− The transfer tube stops,
− The variable main pump swings back, and the
delivery pistons stop.
Cable remote − The supply voltage to the cable remote control
control system, with the exception of that for the horn,
is switched off.
Control cabi- − The EMERGENCY STOP" symbol is high

net lighted in colour and flashes in the display unit.

AP15_001_1701EN 35
 Safetyequipment

3.2.2 Function check It is only possible to intervene quickly in the event of danger if all the
EMERGENCY STOP buttons are working properly.

" Switch the pump and agitator on.

" Press one of the EMERGENCY STOP buttons.

å The agitator must come to a halt immediately.
å The variable main pump swings back, and the delivery pis

tons stop.

" Check all EMERGENCY STOP and STOP buttons on the ma

chine and on the remote control in the same way.

36 AP15_001_1701EN
 Safetyequipment

3.3 Agitator safety cutout

ISO13849
1:2015 category1 PLc

Intervals for inspection by a
annually
subject expert
Intervals for function checks Before the machine is used each time

Danger
Risk of injury when the agitator is operating and the transfer tube is
switching.

A defective agitator safety cutout can cause you to believe that the
machine is safe, even though this is not really the case. This can
lead to the agitator continuing to run or the transfer tube switching
over when the grille is open.

You must therefore check the function of the agitator safety cutout
before you start each pumping job.

You must stop work if you open the grille, but

 the agitator continues to run, or
 the transfer tube continues to switch over, or
 the concrete pump does not run to its end position.

AP15_005_1701EN 37
 Safetyequipment

3.3.1 Description of the This machine is fitted with an agitator safety cutout (RSA). As soon
functions as you open the grille, the signal between the transponder and read

ing head is broken. This causes the agitator to halt and the pressure
to be dumped from the accumulator (if fitted) or the change−over
valve to be de−energized, i.e. the transfer tube will no longer be
able to switch over. In addition, the delivery pistons return to the end
position and the concrete pump stops.

1 2 3

AP15_005_1701EN 1

Pos.0 Designation
1 Reading head (on the hopper − example illustration)
2 Green and red LEDs
3 Transponder (on the grille)

Safety action:
− The agitator stops.
− The accumulator dump valve (if fitted) is opened and the accumu

lator (if fitted) is emptied
− The change−over valve is de−energized (depending on the ma

chine)
− The transfer tube stops.

Technical action:
− The delivery pistons return to the end position
− The concrete pump stops

38 AP15_005_1701EN
 Safetyequipment

3.3.2 Function check

AP15_005_1701EN 2

" Open the grille with the concrete pump running.

å The transponder signal is broken.
å The agitator must come to a halt immediately.
å The transfer tube must no longer switch over.
å The concrete pump must run to the end position and halt.

AP15_005_1701EN 39
 Safetyequipment

Safety action:
å The agitator must come to a halt immediately.
å The hydraulic fluid pressure in the accumulator (if fitted) is
dumped (see the pressure gauge).
å The change−over valve is de−energized (depending on the
machine).
å The transfer tube must no longer switch over.

Technical action:
å The concrete pump must run to the end position and halt.

Note
The LEDs on the evaluation device indicate the following information:
 The green LED flashes for 8seconds during the initialization pro
cess.
 The green LED lights up during normal operation when the grille is
closed.
 The green LED flashes when the grille is open.
 The red LED lights up when there is a fault with the evaluation de
vice.

310 AP15_005_1701EN
 Safetyequipment

3.3.3 Acknowledging the The agitator is secured against unexpected restarts. When the ma

agitator safety cutout chine is set up, and when the agitator safety cutout is triggered, it
must be acknowledged on the operating panel before the concrete
pump can be switched back on.

Danger
Risk of injury when the agitator is operating and the transfer tube is
switching. Before acknowledging the agitator safety cutout, check
that no−one is in any danger.

Note
You must acknowledge the agitator safety cutout on the operating
panel and switch the concrete pump off and on again before restart
ing the agitator.

AP15_005_1701EN 3

Pos.0 Designation
1 Toggle switch on the operating panel:
Acknowledging the agitator safety cutout

" Activate the Acknowledge the agitator safety cutout" toggle

switch.

AP15_005_1701EN 311
 Safetyequipment

3.4 Separating protective devices

ISO13849
1:2015 category1 PLc

Intervals for inspection by a
annually
subject expert
Intervals for function checks Before the machine is used each time

3.4.1 Description of the A protective device is an obstacle (e.g.cover) located between the
functions machine operator and the danger zone.

3.4.2 Function check Below you will see an example figure of a stationary concrete pump
and the separating protective devices fitted.

" Check whether the protective devices are present, fully func

tional and securely mounted.

312 AP15_004_1701EN
 Safetyequipment

1 2 3 4

7 6 5
AP15_004_1701EN 1

Example illustration

Pos. 0 Safety equipment

1 Covers over the switch cylinders
2 Side protection doors
3 Exhaust guard
4 Grille on V−belt (depending on the machine)
5 Water box cover
6 Spray guard
7 Grille on the hopper

AP15_004_1701EN 313
 Safetyequipment

3.5 Grille

ISO13849
1:2015 category2 PLd

Intervals for inspection by a
annually
subject expert
Intervals for function checks Once a month
As soon as a bar has a residual material thickness of 50% of
Intervals for replacement
height or width, at any point.

3.5.1 Description The grille is a passive safety function (protective device). For techni

of the functions cal reasons, the bar spacing is selected in such a way that allows
concrete with defined particle sizes to flow into the hopper. The bars
are subject to natural wear.

Danger
If the grille is defective, there is a risk that the operator could be
caught in the agitator and seriously injured. Therefore, make sure
that the grille remains fully functional at all times. If the residual ma
terial thickness is reached, you must have the grille replaced by
qualified personnel authorized by Putzmeister.

Once the grille has been replaced, the agitator safety cutout must be
reset. This may only be performed by qualified personnel authorized
by Putzmeister.

314 BP15_009_1608EN
 Safetyequipment

3.5.2 Function check

BP15_009_1608EN 1

" Measure the width(W) and height(H) of the bars in an area

with high wear, preferably in the middle of the grille.

" Measure the width(W) and height(H) of the bars in an area

with low wear (the edge of the grille).

" Compare the values measured.

Note
You must have the grille replaced if one of the residual material thick
nesses is less than 50% of the original material thickness.

" Inspect the grille for any other damage (broken bars, cracked
seams, etc.).

Note
You must have the grille repaired or replaced if you detect any dam
age.

BP15_009_1608EN 315
 Safetyequipment

3.6 Plates

Intervals for inspection by a

annually
subject expert
Intervals for function checks Once a month

3.6.1 Description Plates on the machine warn operators of dangers that cannot be pre

of the functions vented by means of the design.

Note
You will find the locations of the plates on the machine circuit dia
grams, which indicate which plate should be affixed where.

3.6.2 Function check

" Check whether the plates that are required according to the
plate location plan have been affixed on the machine and are
legible.

" Replace any missing, damaged or illegible plates with new

ones.

316 BP15_010_1202EN
 Specialmodesofoperation

4 Special modes of operation

The machine’s special operating modes are described in this

chapter. Special operating modes are, in particular:
− Operation in situations of increased risk
− Operation with limited functions

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

AP16_001_1609EN 4I
 Specialmodesofoperation

4II AP16_001_1609EN
 Specialmodesofoperation

4.1 Emergency operation The hydraulic control valves are built into the pump control system.
– pump function They are only for emergency manual operation of the machine when
the control system fails.

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

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

the pump control system, this is located behind a protection door.

Note
For the location of the pump control system, refer to the overview at
the start of the chapter
General technical description".
Familiarize yourself with the functions of the pump control system by
reading the notices affixed to it.

AP16_005_1701EN 41
 Specialmodesofoperation

1
2

AP16_005_1701EN 1

Pos.0 Designation
1 Transfer tube change−over valve
2 Delivery cylinder emergency control lever

Operating the pump control system

Delivery cylinder If the control system fails, you can operate the delivery cylinders
emergency control using the emergency control lever.
lever
" Press the delivery cylinder emergency control lever to the left
or right.
å The corresponding delivery cylinder starts to move.

Transfer tube change− If the control system fails, you can switch over the transfer tube using
over valve the transfer tube change−over valve.

" Once the accumulator is filled (see accumulator pressure

gauge), press the transfer tube change
over valve.
å The transfer tube switches over.

42 AP16_005_1701EN
 Specialmodesofoperation

4.2 Agitator emergency If the control panel has failed, you can use different directions of
operation rotation to manually operate the agitator from the hydraulic control
block illustrated below.

Note
The water pump lever must be in the zero position so that the fluid
flow is directed to the agitator control block.

Note
How the emergency operation devices are assigned may vary de
pending on the mounting position. It may also be the case that the
control block is installed rotated through 90°. Familiarize yourself
with the functions of the control block by reading the notices affixed
on site.

AP16_002_1609EN 43
 Specialmodesofoperation

Operating the agitator emergency operation device

AP16_002_1609EN 1

Example illustration

Pos.0 Designation
1 Agitatoron − agitation direction away from the delivery cyl

inder
2 Agitatoron − agitation direction towards the delivery cylin

der

" To change the agitator’s direction of rotation manually, actuate

one of the emergency operation devices.

44 AP16_002_1609EN
 Specialmodesofoperation

4.3 Recovering the ma- If a fault occurs on the machine and cannot be rectified immediately,
chine after faults you must stop site use and take steps to recover the machine. The
occur delivery system may become damaged if concrete sets in it.

Note
Recovery of the machine is a special operating mode. This special
operating mode is not suitable for continuing site use.

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

The machine’s EMERGENCY STOP buttons do not work while the

machine is being recovered (e.g. in the event of a power failure). For
this reason, you must cover all EMERGENCY STOP buttons for the
duration of machine recovery.

Have a second person help you, as the steps required can be better
carried out with two people.

AP16_006_1701EN 45
 Specialmodesofoperation

4.3.1 Recovery with on- As long as the machine’s hydraulic drive unit is working, you can re

board equipment cover the machine using on
board equipment.

Emergency operation The pump control system is equipped with hydraulic control valves
– pump function which can be operated by hand. They are only for emergency man

ual operation of the machine when the control system fails.

1
2

AP16_006_1701EN 1

Pos.0 Designation
1 Transfer tube change−over valve
2 Delivery cylinder emergency control lever

46 AP16_006_1701EN
 Specialmodesofoperation

" Press the delivery cylinder emergency control lever to the left
or right.
å The corresponding delivery cylinder starts to move.

" Once the accumulator is filled (see accumulator pressure

gauge), press the transfer tube change
over valve.
å The transfer tube switches over.

" Pump the concrete out of the delivery line, back into the
hopper.

" Clean the delivery line as described in the Cleaning" section

of the Pumping operations" chapter.

" Clean the hopper, delivery cylinder and S transfer tube as de

scribed in the Cleaning" section of the Pumping operations"
chapter.

Note
If the machine breaks down completely, please contact the Putzme
ister After Sales department. The service technician will tell you what
you can do to recover the machine.

AP16_006_1701EN 47
 Specialmodesofoperation

48 AusgleichsseiteEN
 Maintenance

5 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 5I
 Maintenance

5II BP09_001_9405EN
 Maintenance

5.1 Daily tasks You must carry out daily checks, function checks and maintenance
tasks so that your machine remains fully functional and is safe in
operation. The tasks are described in detail in the Cleaning" sec

tions of the Safety regulations" and Pumping operations" chapters.
The following tables summarize these once more. The criterion col

umn briefly describes the points you need to observe. The checks
must be carried out at the beginning of each new shift in the case of
machines in continuous operation.

Caution
You must rectify (or have rectified) any defects immediately you
discover them during your checks.

5.1.1 Daily visual checks You must lubricate your machine and check it each time before you
start to use it.

Assembly Checking Criterion

available and in a fully functioning
Safety devices
condition
General
Lubrication points sufficient lubrication

Engine Oil level sufficient

Agitator gearbox Oil level sufficient

Oil level sufficient

Hydraulic system Condensation in the hydraulic fluid
drain off if present
reservoir
Radiator Contamination sufficient cooling possible

Spacer flange securing wire undamaged securing wire

The piston rods must be completely

Water level
Water box covered
no hydraulic fluid or concrete in the
Water contamination
water box
Inner wall and wear ring no mechanical wear
Transfer tube
Spectacle wear plate no mechanical wear

Pipes no leaks or fractures

Centralized lubrica

lubrica
tion system Grease gun sufficient grease reserve

designed for the delivery pressure, laid

Delivery line Suitability and wear according to the rules of technology,
wall thickness sufficient

Compressor Oil level sufficient

AP09_002_0308EN 51
 Maintenance

5.1.2 Function check You must always check all the control and monitoring functions plus
the stroke times of the pump before using it.

Assembly Function checks and inspections Criterion

Measure stroke times compare against test reading

General Engine start up/engine off fully functional

All operating elements fully functional

Vacuum meter for the suction filters in the green zone

Red button for the pressure filters red button remains depressed

Agitator cut−out fully functional

Hydraulic system
Drive cylinders oil−tight

Switch cylinders oil−tight

Lines and threaded unions oil−tight

Control cabinet All operating elements fully functional

Remote control All operating elements fully functional

52 AP09_002_0308EN
 Maintenance

5.1.3 When pumping You must monitor the operational status of your machine and lubri

cate it as required.

Assembly Checking Criterion

General All lubrication points lubricate as required

Switching shaft bearings and seal

Transfer tube Bearings and seal on the pressure no cement−coloured oil and grease
connection mixture or slurry cement may escape
from the bearings
Hopper Mixer shaft bearings and seal

Instruments Monitor all in the normal range

5.1.4 After every job You should carry out the following service operations and checks
after every job.

Assembly Activities and checks Criterion

Cleaning
General
All lubrication points sufficient lubrication

Water box Drain off water

Check inner wall and wear ring no mechanical wear

Transfer tube
Check sealing gap gap < 1mm

Coupling and seal ring on pressure

Delivery line grease
pipe

AP09_002_0308EN 53
 Maintenance

5.2 Maintenance work The maintenance tasks as required" must be carried out if faults are
discovered during the daily checks. Other maintenance work is re

quired at regular intervals. The maintenance cards describe all the
maintenance tasks which are within your means to carry out. You can
find these further on in this chapter. The maintenance tasks have
been listed in the tables according to their time intervals.

5.2.1 As required You must carry out the work described below if you determine that it
is necessary in the course of your daily checks.

Assembly Activity / Maintenance card

Replace the fluid filter

Hydraulic system Replace hydraulic hoses

Tighten / change flared screwed joints
Tighten bolts on the spacer flange
Core pump
Replace delivery pistons
Measure the wall thickness
Adjust the transfer tube
Replace the spectacle wear plate
Transfer tube
Tighten the clamping bolts on the switch lever
Replace switching shaft bearings and seals
Pressure connection − replace bearings and seals
Replace bearings and seals
Agitator
Full transmission oil change
Check wear
Delivery line
Check coupling to pressure pipe

54 AP09_001_0902EN
 Maintenance

5.2.2 Regular maintenance Regular maintenance tasks must be carried out in addition to the
tasks daily visual inspections and function checks and servicing oper

ations.

Caution
The maintenance intervals are specified for normal wear. You will
have to shorten the maintenance intervals accordingly if you are
pumping very abrasive media.

Weekly You must tighten the fastening bolts on the vibrator and clean the
compressor once a week.

Every 500 hours The following tasks must also be carried out after 500 operating
of operation hours, but at least once a year. In addition, a subject expert should
inspect the pump and the delivery line.

Assembly Activity / Maintenance card

Check threaded unions

General Output test

Function test
Full fluid change and clean fluid sump (replace all filters)
Check LEDs on the valves and magnetic switches
Check the agitator cut−out (function check)
Hydraulic system
Clean hydraulic fluid radiator and check function
Check temperature sensor
Check hydraulic accumulator, top up and adjust if necessary
Centralized
Check centralized lubrication system
lubrication system
Check that all magnetic switches are positioned and functioning
Electrical system
correctly

AP09_001_0902EN 55
 Maintenance

Assembly Activity / Maintenance card

Extend and retract all cylinders to the stop (expel water)
Check the condition of the piston rods

Core pump Check the seals on the piston rods

Check the bolts on the spacer flange
Check the delivery pistons
Check for wear, measure wall thickness
Check setting
Check tightening torque of the switch lever clamping bolts
Transfer tube
Check the ball cups for the switch cylinders
Check the switching shaft bearings and seals
Check the pressure connection bearings and seals
Change transmission oil
Agitator
Check mixer shaft bearings
Full oil change in accordance with manuacturer’s Operating Instructions
Compressor Clean air filter (wash out) in accordance with manufacturer’s Operating
Instructions
Clean intake filter
Water pump
Replace the HW520 and WP50 plastic rollers
Maintenance information in accordance with manufacturer’s Operating
Engine
Instructions

56 AP09_001_0902EN
 Maintenance

5.3 Residual risks during maintenance, inspection and repair work

5.3.1 Personal protective See the "Safety regulations" chapter for personal protective equip

equipment ment requirements.

Danger
Risk of serious physical injury if personal protective equipment is
notworn. Always wear your personal protective equipment during
maintenance, inspection and repair work. Safety helmet and safety
footwear are a basic requirement. Other personal protective equip
ment is required as listed in the "Safety regulations" chapter.

5.3.2 Personnel Maintenance, inspection and repair work must only be carried out
requirements byqualified personnel. "Qualified personnel" means those who have
completed specialist training for carrying out such work. This training
qualifies them to carry out the activity concerned.

5.3.3 Auxiliary devices Adequate workshop equipment is absolutely necessary for carrying
out maintenance, inspection and repair work.

If you do not have qualified personnel, suitable workshop equipment

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

BP09_020_1108EN 57
 Maintenance

5.3.4 Residual risks During maintenance, inspection and repair work, there are
particularrisks of an accident, because for certain activities,
protective devices must be removed, for example. There follows
alist of residual risks in particular, which may be present during
maintenance, inspection and repair work.

Danger
There is a risk of falling when working above the ground or floor.
Youshould therefore always ensure that you are secure by using
safety harnesses, railings or walkway barriers. Never use machine
parts as climbing aids. Keep all handgrips, steps, railings, platforms
and ladders free from dirt, snow and ice.

Danger
In the area between the mixer drum and frame, there is a risk of
being pulled in, crushed or injured by shearing. Working in this area
is only allowed if the mixer drum is secured with the mixer drum
holder. Read the operating instructions from the truck mixer manu
facturer for information about this.

Danger
Risk of injury through skin contact with functional fluids
(e.g.hydraulic fluid). Avoid contact with functional fluids.
Wear your personal protective equipment. Take note of the safety
data sheets produced by the manufacturer of the functional fluids.

Danger
Risk of burning from hot functional fluids and hot surfaces.
Allow hot functional fluids and hot surfaces to cool first.
Wear your personal protective equipment. Cover hot surfaces
withheatresistant materials.

58 BP09_020_1108EN
 Maintenance

Danger
Risk of injury from pressurised hydraulic fluid. Put the machine out
ofservice before starting maintenance, inspection and repair work.
Depressurise the hydraulic system. Dump pressure from the accu
mulator.

Danger
Risk of injury from compressed air. Put the machine out of service
before starting maintenance, inspection and repair work.
Depressurise the compressed air system.

Danger
Risk of injury from whipping hydraulic hoses. Mechanically pre
stressed hydraulic hoses may lash out when loosening the threaded
union. Wear your personal protective equipment. Secure the
hydraulic hoses tightly in place when loosening the threaded unions.

Danger
Risk of injury from the machine starting unexpectedly. Before starting
maintenance, inspection and repair work, put the machine out of
service and secure it against unexpected restarting (e.g. remove
ignition key and put it in your pocket, place a warning plate on the
controls). If this is not possible, ask someone to stand guard who
can prevent the machine from starting up unexpectedly.

BP09_020_1108EN 59
 Maintenance

5.4 General tightening Tightening torques depend on:

torques − bolt grade
− thread friction
− bolt head bearing area

The values given in the following tables are for guidance. These va

lues should only be used if no other values are specified in the rel

evant chapters of the Operating Instructions or in spare parts sheets.

Caution
You must always use bolts of the same size and property class when
you have to replace bolts. Bolts with adhesive in the locking threads
and selflocking nuts must always be replaced after removal.

5.4.1 Set screws and nuts You will find the maximum tightening torques for set screws and nuts
in spare parts list.

Note
For threaded unions, tighten the union nut using a spanner. While
doing so, you must use another spanner to hold the threaded con
nection in place.

10400100

Tighten threaded union

510 BP09_022_1309EN
 Maintenance

5.4.2 Flared screwed joint, Every time the joint has been undone, the union nut must be tigh

reassembly tened again securely without excessive force.

Flared screwed joints

External MA [Nm] External MA [Nm]
diameter (RAD)/ diameter (RAD)/
Type Type
6 L 20 16 S 130
8 L 40 18 L 120
10 L 45 20 S 250
L 55 25 S 400
12
S 80 30 S 500
15 L 70 38 S 800
* RAD = pipe external diameter
* MA = tightening torque

" Tighten the union nut using a spanner. While doing so, you
must use another spanner to hold the threaded connection in
place.

5.4.3 Profiled ring joint, After each time the joint is undone, the union nut must be tightened
reassembly again securely without excessive force to ensure that the joint is
tight.

BP09_022_1309EN 511
 Maintenance

5.4.4 WALFORMplus Below you will find an overview of the most important components in
threaded union the WALFORMplus threaded union. The next section describes what
must be borne in mind during reassembly of WALFORMplus
threaded unions.

1 2

4 3
BP09_022_1309EN 1

No. 0 Designation
1 Threaded connection
2 Union nut
3 Pipe
4 Seal

512 BP09_022_1309EN
 Maintenance

5.4.5 WALFORMplus For reassembly of the WALFORMplus threaded union, proceed as

threaded union, follows:
reassembly

" Check the thread for cleanliness and damage.

" Clean the thread, and if necessary, replace the parts with a
damaged thread.

" Each time the connection is loosened, check the gasket for
damage, and replace it if necessary.

" For threaded unions made of rust
proof steel, grease the

thread and the reshaped area of the pipes with an adequate
amount of EATON
ABF grease.

" Pull the gasket onto the reshaped pipe as far as the stop.

Note
Firmly tighten the union nut again using the same torque as for initial
installation.

" Tighten the union nut using a spanner. While doing so, you
must use another spanner to hold the threaded connection in
place.

BP09_022_1309EN 513
 Maintenance

Note
The tightening torques are guide values, and only apply to optimum
conditions. The torques may deviate substantially because of toler
ance influences, pipes fitted under tension and incorrect lubrication.

Tightening torques
WALFORMplus threaded unions
External MA [Nm] External MA [Nm]
diameter (RAD)/ diameter (RAD)/
Type Type
6 L 30 18 L 110
8 L 35 22 L 140
10 L 40 28 L 210
12 L 55 35 L 300
15 L 80 42 L 400
* RAD = pipe external diameter
* MA = tightening torque

Tightening torques
WALFORMplus threaded unions
External MA [Nm] External MA [Nm]
diameter (RAD)/ diameter (RAD)/
Type Type
6 S 35 20 S 150
8 S 40 25 S 210
10 S 55 30 S 280
12 S 70 38 S 410
16 S 110
* RAD = pipe external diameter
* MA = tightening torque

514 BP09_022_1309EN
 Maintenance

5.5 Functional fluids This section lists all the functional fluids used in your machine.

Caution
Never use hydraulic fluids or lubricants with additives such as mo
lybdenum. Such additives can attack the bearings.

5.5.1 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).

(see also http://www.putzmeister.de/deu/Hydraulicfluids.htm)

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.

BP09_004_1703EN 515
 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 con
cerned.

When hydraulic fluids of different viscosity grades are mixed, the

new viscosity is determined by the mix ratio. Loss of quality is poss
ible 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 (German Engineering Federation) changeover

guidelines and manufacturer instructions when carrying out a fluid
change. Please contact the manufacturers concerned if you have
any queries regarding the suitability and miscibility of hydraulic
fluids.

516 BP09_004_1703EN
 Maintenance

5.5.2 Level of contaminant Level of contaminant 19/16/12 in accordance with ISO4406 is speci

fied for lubrication and the hydraulic system. You can find the level of
contaminant of the initial filling from the test report on the machine
card.

5.5.3 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 lu

bricants or hydraulic fluids used. Please consult Putzmeister, Depart

ment APS (After Sales) and request our analysis kit (material
no.257260.004). We will carry out a lubricant analysis to determine
the cause.

5.5.4 Storage of lubricants Do not store oils and greases in the open air. Weather variations may
cause water to be absorbed through the bung hole.

Only ever store the barrels lying on their side and supported on
timber blocks, with the bung hole facing upwards.

Environmental protection
You must carefully collect all functional fluids, e.g. used oil (including
biologically degradable oils), filters and auxiliary materials and dis
pose of them separately from other waste.You must keep used oils of
various types separate in order to keep disposal costs as low as
possible.

Observe the national and regional regulations applicable to your

area. Only work with waste disposal companies who are approved
by the responsible authorities.

BP09_004_1703EN 517
 Maintenance

5.6 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.

518 BP09_016_0708EN
 Maintenance

Caution
The following points must be complied with in order to prevent
damage:
 You must warm the machine up briefly if you wish to start using it
when the hydraulic fluid temperature is below 0_C. To do this,
engage the power take−off, switch off the concrete pump and
allow the machine to idle for a few minutes.
 The machine should not be placed under full load until the tem
perature of the hydraulic fluid (VG46) has risen above 10_C.
 The ideal temperature for the hydraulic fluid (HLP or HEES, VG46)
is between 40_C and 70_C.

Danger
Never mix hydraulic fluids of different types, i.e. do not mix biologi
cally degradable hydraulic fluids with mineral hydraulic fluids etc.

BP09_016_0708EN 519
 Maintenance

5.6.1 Oils
Agitator Slewing gear Transfer
Rotor gearbox
gearbox transmission gearbox
Requirements
DIN 51 517 DIN 51 517 DIN 51 517
standard
Characteristics synthetic mineral mineral see spare
p 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.

520 BP09_016_0708EN
 Maintenance

5.6.2 Greases
Greasing Centralized Greasing the pump
(manual) lubrication system tube in rotor pumps
Marking in
accordance K2K−30 K1K−30 
with DIN 51 502
Requirements
DIN 51 825 DIN 51 825 
standard
Characteristics mineral, lithium soap 
Viscosity grade, NLGI Class 2 NLGI Class 1

NLGI Class DIN 51818 DIN 51818
Material no. 360000.009 360001.008 290207.008

Note
We recommend the following grease, rather than those specified in
the lubricant table, should you wish to fill the centralized lubrication
system with a low temperature grease in extremely cold conditions:
Marking in accordance with DIN51502: KE2G−60, NLGI Class2

BP09_016_0708EN 521
522 5.6.3 Hydraulic fluids
Type Mineral fluid Synthetic ester Aqueous solutions
Model HLP HEES HFC
Classification
DIN 51502

Maintenance
ISO 6743/0
Requirement
DIN 51524 Part2  
ISO 6743 Part 4  
VDMA 24318 24568 24317/24320
Other   7th Luxembourg Report
Viscosities
DIN 51519
ISO 3448
2
mm /s ISO VG 32 46 68 46 46
Use
15_C to +80_C
10_C to +90_C 0_C to +95_C
10_C to +80_C
20_C to +60_C
Particular char

 biodegrades quickly non−readily flammable
acteristics
Initial filling
Material no. 490984 000171.007 279845.009 484527 239879.002
BECHEM HYDROSTAR FUCHS HYDROTHERM
Manufacturer 
HEES46 46M
Changeover guidelines
VDMA  24569 24314

see also http://www.putzmeister.de/deu/Hydraulicfluids.htm

BP09_017_1703EN
 Maintenance

Maintenance cards

In this section you will find the maintenance cards necessary for this
machine. The table of contents includes a summary of the mainten

ance cards in numerical order, you will find an alphabetical summary
in the Index of key words under the entry for Maintenance cards".

BP09_013_1205EN 523
 Maintenance

524 BP09_013_1205EN
 Maintenancecard
00−001
Page 1 of 2

00–001 Visual checks This maintenance card describes visual checks that you must
carryout before commencing any maintenance work. You will find
the maintenance intervals in the maintenance summary at the start
ofthis chapter.

Note
There are specific risks of an accident associated with maintenance,
inspection and repair work.
For this reason, read the chapter "Safetyregulations" and the
description of the "Residual risks during maintenance, inspection
and repair work" at the start of the chapter entitled "Maintenance"
(i.e. this chapter).

See also the maintenance cards:

Filter change
Hoses

No special tools required.

Danger
Inspect the electrical cables particularly closely and carefully.
Thereis a danger of flash overs from defective cables, particularly
when there is high air or ambient humidity. There is a danger of fire
and explosion through the formation of sparks when the machine is
used in a potentially explosive atmosphere.

WK00_001_1109EN 525
 Maintenancecard
00−001
Page 2 of 2

General The general visual inspections listed below should always be carried
out before any maintenance work, and also each time before starting
work with the machine.

" Check the fill levels of the functional fluids.

" Check that all safety equipment is available and in a fully

functioning condition.

Electrical system Should you locate any damage to the electrical system, you must
have the damage rectified immediately by a qualified electrician.

" Check that all electrical connections are secure and free from
corrosion.

" Check that the electrical cables have no breaks.

" Check the insulation on the electrical cables.

Hydraulic system Timely detection and rectification of damage to the hydraulic system
can prevent lengthy downtimes and high repair costs.

" Check that the displays on the vacuum meter of the suction
filters are still in the green range. The suction filters must be
replaced if the displays are in the red range.
Maintenance card: Filter change

" Check the contamination indicators on the boom filters.

Thefilters are in order if the red button remains depressed.
Thefilter must be replaced if the red button pops out.
Maintenance card: Filter change

" Check the fluid cooler for contamination and deposits.

" Check all hydraulic hose lines for leaks.

Maintenance card: Hoses

" Check all screwed hydraulic screw
couplings for tightness

andleaks.
Maintenance card: Hoses

526 WK00_001_1109EN
 Maintenancecard
03−002
Page 1 of 2

03–002 Function checks This maintenance card describes the inspection of machine func

tions. The inspections are carried out with the machine running. You
will find the service intervals in the maintenance summary at the start
of this chapter.

Note
There are specific risks of an accident associated with maintenance,
inspection and repair work.
For this reason, read the chapter "Safetyregulations" and the
description of the "Residual risks during maintenance, inspection
and repair work" at the start of the chapter entitled "Maintenance"
(i.e. this chapter).

No further maintenance cards required.

The following special tools are required:

Pressure gauge and connections for the tapping points shown in the
hydraulic circuit diagram

Note
Only qualified personnel authorized by us may carry out work on the
hydraulic system. Notify the Putzmeister After Sales department or
the dealer/agent who looks after you immediately should you find
any irregularities.

" Measure the pressures generated by the pumps, using the

measuring equipment specified directly on the pumps, and
compare your results with the values specified in the test
reading.

" Check the proper functioning of the pressure−relief valves in

the high pressure circuit and the pressure accumulator.

WK03_002_1109EN 527
 Maintenancecard
03−002
Page 2 of 2

528 WK03_002_1109EN
 Maintenancecard
03−026
Page 1 of 8

03–026 Checking the accumulator This maintenance card describes how to check the accumulator pre

charge pressure. In Germany, the maintenance intervals are pre

scribed by the IndustrialHealth& SafetyOrdinance [Betriebsicher

heitsverordnung (BetrSichV)]. Please note any applicable regulations
in your country of use.

Note
There are specific risks of accidents associated with maintenance,
inspection and repair work. For this reason, read the chapter

Safetyregulations" and the description of the
Residualrisks during
maintenance, inspection and repair work" at the start of the chapter
entitled
Maintenance" (i.e.this chapter).

No further maintenance cards required.

No special tools required.

WK03_026_1604EN 529
 Maintenancecard
03−026
Page 2 of 8

Danger of explosion
Use only nitrogen to fill the accumulator. There is a danger of ex
plosion if substances such as compressed air or oxygen are used.

Note
Check the accumulator precharge pressure once the hydraulic fluid
has warmed up to its operating temperature (of 50_C to 70_C).

The setpoint value for the accumulator precharge pressure can be

found on the hydraulic circuit diagram as item120 and in the test
reading for the concrete pump under the entry
Accumulator pre
charge pressure". The hydraulic circuit diagram and the test reading
can be found in the documentation binder in the
Technicaldata"
file.

The actual value you measure must not be more than 15% below the
setpoint value specified.

530 WK03_026_1604EN
 Maintenancecard
03−026
Page 3 of 8

2
3

5
WK03_026_1604EN 1

Pos. 0 Designation
1 Accumulator
2 Transfer tube change−over valve
3 Delivery cylinder emergency control lever
4 Transfer tube damping cock
5 Accumulator dump valve

Note
You can observe the pointer on the pressure gauge slowly going
down as you slowly release the accumulator pressure. Once the
accumulator precharge pressure actually present is applied, the
pressure gauge drops suddenly. The value found immediately be
forehand is the present accumulator precharge pressure.

WK03_026_1604EN 531
 Maintenancecard
03−026
Page 4 of 8

" Start the machine up.

" Load the accumulator with hydraulic fluid until the maximum
pressure is shown on the pressure gauge.

" Switch off the engine.

å The accumulator pump halts.
å The accumulator dump valve remains under stress, i.e. the
accumulator pressure is not dumped.

" Operate the Transfertube change
overvalve" and dump the

accumulator pressure slowly.

Note
Depending on the direction in which you operate the emergency
control lever, it is possible for the transfer tube to switch over again.
This depends on the transfer tube position.

" Observe the pressure gauge and read off the accumulator pre

charge pressure.

You must have the accumulator topped up if the actual value is 15%
or more below the setpoint value.

532 WK03_026_1604EN
 Maintenancecard
03−026
Page 5 of 8

Topping up the accu- In Germany, the persons permitted to top up the accumulator, and
mulator the inspection periods, are dependent on the category classified ac

cording to the IndustrialHealth& SafetyOrdinance [Betriebsicher

heitsverordnung (BetrSichV)] and on the maximum permissible pres

sure.
− In accordance with 2014/68/EU, hydraulic fluids and nitrogen be

long to the fluids in group 2. Directive2014/68/EU, appendixII,
diagram2 applies.
− The maximum permissible pressure(PS), the volume(Vinlitres)
and the classified category of the accumulator can be found in the
declaration of conformity for the accumulator (see Technicalap

pendix" binder).

" For additional information, please see the following table.

Note
Please note the provisions for
inspection periods for recurring in
spections" that apply in your country.

WK03_026_1604EN 533
 Maintenancecard
03−026
Page 6 of 8

Recurring inspection
in accordance with BetrSichV

Classification of the pressure equipment

External inspection

Stability inspection
Internal inspection
in accordance with article 13 in connec-

Inspector
tion with appendix II of 2014/68/EU, in ac-
cordance with diagram 2

CategoryI, categoryII
− f
CategoryIII (PSv1bar)

CategoryIII (PSu1bar)
2 years
2years 10 years *
10years* 10 years
10years F
CategoryIV

f= to be carried out by subject expert

F= to be carried out by authorized supervision institution
−= no prescribed inspection period
* = in accordance with BetrSichV (Ordinance on Industrial Safety
and Health), Appendix 5, Number 2:
For pressure equipment with gas cushions in hydraulic fluid systems,
recurring internal inspections must be carried out at the latest after
10 years, provided the liquids and gases used do not exert any cor

rosive impact on the equipment walls.

Note
A subject expert for the inspection and filling of accumulators is
someone who has demonstrably been instructed in this activity by an
authorized inspector. The tools and equipment necessary for in
specting and filling pressure vessels must be available to him.

The accumulator must only be filled with nitrogen (see Gas pre
fill
pressure = xxbar").

534 WK03_026_1604EN
 Maintenancecard
03−026
Page 7 of 8

WK03_026_1604EN 2

The hydraulic system contains an accumulator. Before maintenance

work on the hydraulic system, the system must be depressurized.

Danger
Risk of slipping/falling or suffering impact, and even severe injury,
caused by hydraulic fluid escaping under high pressure. The risk
exists if the hydraulic system is not depressurized before mainten
ance work.
Always depressurize all lines before working on the hydraulic sys
tem.
Be aware that if threaded connections are unusually difficult to open,
it may indicate that pressure is present in the system.
Before maintenance work on the accumulator, the hydraulic system
must be depressurized and the accumulator precharge pressure
must be dumped.

WK03_026_1604EN 535
 Maintenancecard
03−026
Page 8 of 8

536 WK03_026_1604EN
 Maintenancecard
03−010
Page 1 of 4

03–010 Changing the hydraulic This maintenance card describes a full fluid change on the hydraulic
fluid system and cleaning the fluid sump in the hydraulic fluid reservoir.

Note
There are specific risks of an accident associated with maintenance,
inspection and repair work. For this reason, read the chapter "Safety
regulations" and the description of the "Residual risks during main
tenance, inspection and repair work" at the start of the chapter en
titled "Maintenance" (i.e. this chapter).

See also the maintenance cards:

Function checks
Filter change
Hoses

No special tools required.

Note
Cleanliness is of the utmost importance in the maintenance of hy
draulic systems. Prevent any type of dirt and contamination from
entering the system. Even small particles of dirt may cause valves to
be scored, pumps to seize and throttle and control bores to become
blocked.

Hydraulic fluid barrels must stand for some time before the fluid is
removed from them. Do not roll the barrels to the tapping point.
Clean bungs and filler lids as well as the area around them before
opening the hydraulic fluid reservoir.

If possible, you should use a charging set to fill up the hydraulic sys
tem. Never leave the hydraulic fluid reservoir lid open longer than
necessary.

WK03_010_1109EN 537
 Maintenancecard
03−010
Page 2 of 4

Preparation The following tasks must be carried out before starting the full fluid
change:

" Switch off the remote control.

" Switch off the pump.

" Switch off the engine/motor.

" Dump the fluid pressure completely.

Danger
Pressure stored in accumulators must be dumped.

" Secure the machine against unauthorized starting.

" Secure your working area and fix information plates to the
locked controls and setting devices.

Full fluid change

10300400

Draining off the fluid

" Open the fluid drain cock on the hydraulic fluid reservoir and
let the hydraulic fluid drain into a suitable container.

538 WK03_010_1109EN
 Maintenancecard
03−010
Page 3 of 4

Environmental protection
All functional fluids and operating materials, e.g. oils (including bio
logically degradable oils), filters and auxiliary materials must be
carefully collected and disposed of separately, both from each other
and from other waste. Different categories of oil must also be kept
separately from each other. Nationally and regionally applicable dis
posal regulations must be observed for these materials.

Clean fluid sump

" Open the cleaning port on the side of the hydraulic fluid reser

voir.

" Remove all filter elements.

Maintenance card: Filter change

" Wipe out all the openings with a lint−free cloth. Wipe as far into
the reservoir as possible when doing this.

" Change all filters and refit the filter elements.

" Replace any defective hoses.

Maintenance card: Hoses

" Check the seals on the cleaning port and replace these if they
show signs of being defective.

" Close the fluid drain cock and the cleaning port again.

" Check all threaded unions and tighten where necessary. Check
all flared screwed joints.
Maintenance card:Hoses

WK03_010_1109EN 539
 Maintenancecard
03−010
Page 4 of 4

10300500

Filling the reservoir

" Fill the reservoir with new fluid.

Note
Only fill the reservoir through the sieve in the filler pipe. After bleed
ing and a test run, top up the reservoir up to the
Maximum" mark.
Use only the hydraulic fluids specified in the lubricant recommenda
tion.

" Remove the dirt deposits from the hydraulic fluid radiator.

" Check all threaded unions 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 the hydraulic system.

" Carry out several test runs.

" Refit all the safety equipment, markings and notices you have
removed.

540 WK03_010_1109EN
 Maintenancecard
04−002
Page 1 of 4

04–002 Hydraulic hoses This maintenance card describes how to check and replace the
hydraulic hoses. You will find the maintenance intervals in the main

tenance summary at the start of this chapter.

Note
There are specific risks of an accident associated with maintenance,
inspection and repair work.
For this reason, read the chapter "Safetyregulations" and the
description of the "Residual risks during maintenance, inspection
and repair work" at the start of the chapter entitled "Maintenance"
(i.e. this chapter).

No further maintenance cards required.

No special tools required.

MA The tightening torques can be found in the corresponding

Spareparts list.

Note
Check all hydraulic hoses (including hose fittings) with the machine
running.
You must replace the hydraulic hoses at the slightest sign of damage
or even mere indications of threatened damage.

WK04_002_1110EN 541
 Maintenancecard
04−002
Page 2 of 4

Environmental protection
All functional fluids and operating materials, e.g. oils (including bio
logically degradable oils), filters and auxiliary materials must be
carefully collected and disposed of separately, both from each other
and from other waste. Different categories of oil must also be kept
separately from each other. Nationally and regionally applicable dis
posal regulations must be observed for these materials.

Leaking
hydraulic hoses

10400800

Check hydraulic hoses

Dark and moist patches on the fitting are external signs of incipient
damage. Check:
− the hydraulic hoses for kinks, cracks or a porous surface and
− whether the hydraulic hoses have been laid without restrictions.

Note
Beware of strong sunlight, the action of heat and the effects of
chemicals.

542 WK04_002_1110EN
 Maintenancecard
04−002
Page 3 of 4

Replacing The procedure for replacing hydraulic hoses is as follows:

hydraulic hoses
" Shut down the machine and secure against unauthorized
starting.

" Fully dump any (residual) pressure in the hydraulic system.

Danger
Hydraulic hoses may be mechanically pre−stressed. There is a risk
of injury from whipping hoses.

" Take care when undoing the joints.

" Close the connection points with a plug immediately you have
removed the old hydraulic hoses. No dirt may enter the hy

draulic circuit and the hydraulic circuit must not run empty.

Danger
Hydraulic hoses should not be more than six years old, including a
storage time of two years. Take note of the date of manufacture on
the hydraulic hoses.

" Keep the hydraulic hoses free from dirt.

" Fit the hydraulic hoses to be free from bends or points of ab

rasion.

" Bleed the hydraulic system.

" Carry out a test run and inspect all hydraulic hoses again after
fitting new hydraulic hoses.

WK04_002_1110EN 543
 Maintenancecard
04−002
Page 4 of 4

Flared screwed joints

10400100

Tightening flared screwed joint

" Check whether the flared screwed joints are tight.

Note
You may only tighten leaking flared screwed joints with the permitted
tightening torque. Tighten the flared screwed joints until you clearly
feel an increase in the force required if you do not have a torque
wrench available. You must replace these flared screwed joints if
leaking continues.

The tightening torques can be found in the table
Flared screwed

joints" at the start of this chapter.

544 WK04_002_1110EN
 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.

Note
There are specific risks of an accident associated with maintenance,
inspection and repair work.
For this reason, read the chapter "Safetyregulations" and the
description of the "Residual risks during maintenance, inspection
and repair work" at the start of the chapter entitled "Maintenance"
(i.e. this chapter).

No further maintenance cards required.

No special tools required.

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_1109EN 545
 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.

546 WK04_005_1109EN
 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.

Note
There are specific risks of an accident associated with maintenance,
inspection and repair work.
For this reason, read the chapter "Safetyregulations" and the
description of the "Residual risks during maintenance, inspection
and repair work" at the start of the chapter entitled "Maintenance"
(i.e. this chapter).

No further maintenance cards required.

No special tools required.

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_1109EN 547
 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.

548 WK04_012_1109EN
 Maintenancecard
04−012
Page 3 of 6

Changing

1. 3

2.
4.
3.

WK04_012_1109EN 1

No. 0 Designation
1 Lid
2 Hexagon nut
3 Plug
4 Drain cock

WK04_012_1109EN 549
 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.].
å 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.].

550 WK04_012_1109EN
 Maintenancecard
04−012
Page 5 of 6

WK04_012_1109EN 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_1109EN 551
 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.

552 WK04_012_1109EN
 Maintenancecard
04−013
Seite 1 von 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.

Note
There are specific risks of an accident associated with maintenance,
inspection and repair work.
For this reason, read the chapter "Safetyregulations" and the
description of the "Residual risks during maintenance, inspection
and repair work" at the start of the chapter entitled "Maintenance"
(i.e. this chapter).

No further maintenance cards required.

No special tools required.

MA The tightening torques can be found in the corresponding

Spareparts list.

Note
Cleanliness is of the utmost importance in the maintenance of hy
draulic systems. Prevent any type of dirt and contamination from
entering the system. Even small particles of dirt may cause valves to
be scored, pumps to seize and throttle and control bores to become
blocked.

Hydraulic fluid barrels must stand for some time before the fluid is
removed from them. Do not roll the barrels to the tapping point.
Clean bungs and filler lids as well as the area around them before
opening.

If possible, you should use a charging set to fill up the hydraulic sys
tem. Never leave the tank lid open longer than necessary.

WK04_013_1109EN 553
 Maintenancecard
04−013
Seite 2 von 6

Caution
Filter elements freely available on the market have too low a flow
rate. You must, therefore, only ever use original Putzmeister filter el
ements in order to prevent damage to the machine.

You must never attempt to clean filter elements. These must always
be replaced.

Environmental protection
All functional fluids and operating materials, e.g. oils (including bio
logically degradable oils), filters and auxiliary materials must be
carefully collected and disposed of separately, both from each other
and from other waste. Different categories of oil must also be kept
separately from each other. Nationally and regionally applicable dis
posal regulations must be observed for these materials.

Preparation The following tasks must be carried out before changing the filter:

" Switch off the hydraulic pumps.

" Switch off the engine/motor.

" Dump the fluid pressure completely.

" Switch off the remote control.

Danger
Pressure stored in accumulators must be dumped.

" Secure the machine against being started up by unauthorized

persons  if you have any key
operated switches, remove the
key and disconnect the supply voltage.

" Secure your working area and fix information plates to the
locked controls and setting devices.

554 WK04_013_1109EN
 Maintenancecard
04−013
Seite 3 von 6

Checking Replace the filter element if the red button on the contamination indi

cator pops out again after being pressed in at operating tempera

ture.

WK04_013_1109EN 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_1109EN 555
 Maintenancecard
04−013
Seite 4 von 6

Changing

WK04_013_1109EN 2

No. 0 Designation
1 Filter element
2 Filter housing

Caution
The filtering process causes dirt and contamination particles to
accumulate in the filter housing. You must therefore clean the filter
housing thoroughly before refitting the new filter element, as other
wise the new filter element will rapidly become clogged again.

556 WK04_013_1109EN
 Maintenancecard
04−013
Seite 5 von 6

" Undo the filter housing(2) and remove the filter element(1).

" Clean the filter housing(2) thoroughly with a cleaning rag.

" Install a new filter element.

Note
Before fitting new filter elements, you must check all Orings and
other seals on the filter elements and replace them if damaged.

" Screw the filter housing back on.

Note
Check the level of the contamination indicator. Always refit the pro
tective lid on the contamination indicator each time this is checked.

WK04_013_1109EN 557
 Maintenancecard
04−013
Seite 6 von 6

558 WK04_013_1109EN
 Maintenancecard
04−019
Page 1 of 4

04–019 DEF delivery pump filter This maintenance card describes how to change the filter element of
change the DEF delivery pump.

Note
There are specific risks of accident associated with maintenance,
inspection and repair work. For this reason, read the chapter

Safetyregulations" and the description of the
Residualrisks during
maintenance, inspection and repair work" at the start of the chapter
entitled
Maintenance" (i.e.this chapter).

No further maintenance cards required.

No special tools required.

Danger
Risk of injury from rotating and hot components.
Carrying out maintenance, repair and cleaning operations on the en
gine and exhaust after treatment system is generally only permitted
once the engine has been switched off and allowed to cool down.
Use your personal protective equipment.
Observe the requirements and recommendations in the engine
manufacturer’s documentation.

WK04_019_1709EN 559
 Maintenancecard
04−019
Page 2 of 4

Caution
Corrosion damage and damage to electrical and electronic compo
nents within the engine compartment caused by leaking DEF lines.
Regularly check that all DEF lines and line connections are correctly
seated and leaktight.
Seal all leakage points (see the
Exhaust after treatment system"
section in the
General technical description" chapter).

Note
Only qualified personnel may replace filter elements.
The filter element must be replaced after every 1000 operating hours
or 3 years, whichever is soonest.
Refer to the engine manufacturer’s documentation for details about
maintenance of the exhaust after treatment system.

Environmental protection
You must carefully collect the filter element and diesel exhaust fluid
(DEF) and dispose of these separately from other waste.

Observe the national and regional regulations applicable to your

area. Only work with waste disposal companies who are approved
by the relevant authorities.

Note
Cleanliness is of the utmost importance in the maintenance of the
exhaust after treatment system. Prevent dirt or other contamination
from entering the system. Even small particles of dirt may cause
valves to become scored, pumps to seize and throttle and control
bores to become blocked.

560 WK04_019_1709EN
 Maintenancecard
04−019
Page 3 of 4

DEF delivery pump

1

WK04_019_1709EN 1

Pos.0 Designation
1 DEF delivery pump
2 Lid
3 Compensating device
4 Filter element

WK04_019_1709EN 561
 Maintenancecard
04−019
Page 4 of 4

" Shut down the engine.

" Allow the engine and the exhaust after treatment system to
cool down.

" Disconnect the cable connections of the DEF delivery

pump(1) from the electrical connection.

" Place a suitable container under the DEF delivery pump(1) so

you are able to collect escaping diesel exhaust fluid.

" Unscrew the lid(2).

" Pull out the filter element(4) and the compensating device(3).

" Refit the new filter element(4) and the compensating de

vice(3).

" Screw the lid(2) back on with the appropriate torque.

" Connect the cable connections of the DEF delivery pump(1) to

the electrical connection.

" Carry out a test run.

562 WK04_019_1709EN
 Maintenancecard
06−022
Page 1 of 10

06–022 Change of delivery piston This maintenance card describes how to change the delivery pistons
with APP on machines with APP. In APP (Automatic Piston Pull), a ball valve is
fitted in the stroke correction line of each drive cylinder. Machines
with APP have no spacer flange between the piston rod of the drive
cylinder and the delivery piston. You will find the maintenance inter

vals in the maintenance summary at the start of this chapter.

Note
There are specific risks of an accident associated with maintenance,
inspection and repair work. For this reason, read the chapter "Safety
regulations" and the description of the "Residual risks during main
tenance, inspection and repair work" at the start of the chapter en
titled "Maintenance" (i.e. this chapter).

No further maintenance cards required.

No special tools required.

Note
Damage to the delivery pistons must be rectified without delay.
Putzmeister accepts no warranty claims for damage to the machine
resulting from failure to properly observe the maintenance regula
tions.

Danger
Secure the working area. Place warning notices on blocked control
and setting devices.

WK06_022_1109EN 563
 Maintenancecard
06−022
Page 2 of 10

You will have to start up and shut down the machine a number of
times when replacing the delivery pistons. The operations necessary
for this task are described below and must be carried out conscien

tiously.

Shutting down Proceed as follows to shut down the machine:

the machine
" Set the pumping rate to zero.

" Stop the engine.

" Check the high
pressure gauge and wait until the fluid pres

sure in the hydraulic system has been reduced.

" Open the accumulator dump cock on machines with an accu

mulator.

" Close the accumulator dump cock as soon as you can see on
the pressure gauge that the fluid pressure in the accumulator
has declined.

Danger
Dump the accumulator pressure completely on machines with accu
mulators.

Starting up Proceed as follows to start up the machine:

the machine
" Set the throttle to one−third.

" Start up the engine.

" Wait until the engine has reached a steady speed.

Caution
Do not switch the pump on until you are called upon to do so.

564 WK06_022_1109EN
 Maintenancecard
06−022
Page 3 of 10

Opening the water The delivery pistons are withdrawn from the delivery cylinders with
box the piston rod of the drive cylinder in delivery piston replacement. To
make this possible, you must first remove the stop plates in the water
box.
As the delivery pistons are changed from below, the base must also
be removed.

" Shut the machine down.

" Remove the water box cover.

" Remove the two stop plates from the water box.

" Drain the water from the water box and remove the water box
base.

Á
Á
Á
1

2
Á
2

4
5

WK06_022_1109EN 1

1 Water box cover

2 Stop plate
3 Drive cylinder
4 Delivery cylinder
5 Round cord
6 Base with water outlet

WK06_022_1109EN 565
 Maintenancecard
06−022
Page 4 of 10

Shut–off the stroke You must block the drive cylinders in the end position in order now to
correction lines be able to withdraw the delivery pistons from the delivery cylinders.
You must close both stroke correction lines to do this.

APP isolating valve

20202301

The works fits the APP isolating valve in the open state

566 WK06_022_1109EN
 Maintenancecard
06−022
Page 5 of 10

20202302

1 As−fitted position secured against rotation

2 Rotate position

" Undo the bolt on the handle and remove the handle.

" Lift up the guide washer and refit it rotated through 90_.

" Replace the handles and close both isolating valves.

20202303

Isolating valve closed

WK06_022_1109EN 567
 Maintenancecard
06−022
Page 6 of 10

Blocking the drive cyl- You must move the associated drive cylinder to its dismantling end
inders in the end posi- position before you are able to remove the delivery pistons. The pro

tion cedure is as follows:

" Press the Change−over" switch with the concrete pump run

ning at a low delivery rate and hold it down until the concrete
pump switches off.

" You must switch the concrete pump off when the drive cylin

ders have reached their dismantling end position. Then you
can release the Change−over" switch.

" Shut the machine down.

Dismantling end posi

tion

5 1 2 4

3
WK06_022_1109EN 2

1 Hexagon head bolt

2 Delivery piston
3 Round rod
4 Drive cylinder
5 Delivery cylinder edge

" Remove the hexagon head bolt from the delivery piston, secur

ing the piston against rotation with a round rod. Remove the
delivery piston.

" Thoroughly clean the delivery piston edge at the end of the
water box.

568 WK06_022_1109EN
 Maintenancecard
06−022
Page 7 of 10

Caution
Do not use any hard objects or caustic cleaning agents to clean the
delivery cylinder. These might damage the chrome coating.

Replacing the seal You may now replace the worn components on the dismantled
delivery piston.

3
1 2

WK06_022_1109EN 3

1 Hexagon head bolt

2 Flange
3 Delivery piston seal
4 Guide ring
5 Piston body

" Replace the worn parts.

" Grease the new delivery piston heavily with acid−free grease
(e.g. Vaseline).

" Secure the new delivery piston with the hexagon head bolt. Be
sure to use the tightening torque specified.

WK06_022_1109EN 569
 Maintenancecard
06−022
Page 8 of 10

" Start the machine up.

" Advance the piston rod slowly and force the new delivery
piston carefully into the delivery cylinder until the piston has
reached its end position.

" Allow the pump to run on until the other delivery piston has
reached its dismantling end position.

Note
Replace the second delivery piston in the same way.

20202301

Open the isolating valve and secure it against rotation

" Open the two isolating valves when delivery piston replace

ment is completed.

Caution
If the isolating valves remain closed on completion of delivery piston
replacement, the delivery pistons will strike the stop plates in the
water box and there is a danger that the delivery pistons will tear
away from the drive piston rod.

570 WK06_022_1109EN
 Maintenancecard
06−022
Page 9 of 10

20202302

1 As−fitted position secured against rotation

2 Rotate position

" Replace the guide washer so that it is blocked in position,

fitthe handle and bolt it down.

" Fit the base with its water outlet to the water box.

" Fill the water box with water and check that it is not leaking.

" Refit the stop plates.

" Refasten the cover over the water box.

" Then carry out a test run.

WK06_022_1109EN 571
 Maintenancecard
06−022
Page 10 of 10

572 WK06_022_1109EN
 Maintenancecard
07−069
Page 1 of 6

07–069 Replacing the transfer tube This maintenance card describes how to replace the transfer tube
bearing bearing. You will find the maintenance intervals in the maintenance
summary at the start of this chapter.

Note
There are specific risks of an accident associated with maintenance,
inspection and repair work. For this reason, read the chapter "Safety
regulations" and the description of the "Residual risks during main
tenance, inspection and repair work" at the start of the chapter en
titled "Maintenance" (i.e. this chapter).

No further maintenance cards required.

No special tools required.

MA The tightening torques can be found in the corresponding

Spareparts list.

Danger of crushing
A pressurized hydraulic system may cause the machine to move
suddenly, which may result in you being seriously injured if you are
working on the machine. To avoid risk, shut the machine down and
secure it against unauthorized or accidental starting.

Caution
Use only suitable lifting equipment for lifting components.

Note
Wear parts must be replaced in the event of one of the following:
 Severe wear is visible
 Concrete is seeping out

WK07_069_1109EN 573
 Maintenancecard
07−069
Page 2 of 6

When maintenance work is carried out, the machine must have been
shut down. The operations necessary for this task are described
below and must be carried out conscientiously. Perform all machine
functions using the remote control.

Shutting down Proceed as follows to shut down the machine:

the machine
" Switch off the engine.

" Dump the pressures completely.

Danger
Dump the accumulator pressure completely in systems with pressure
accumulators.

Starting up Proceed as follows to start up the machine:

the machine
" If there is a throttle, set it to one third.

" Start up the engine.

" Select a low output.

" Switch the pump on.

574 WK07_069_1109EN
 Maintenancecard
07−069
Page 3 of 6

Removing the transfer The S transfer tube is mounted in the transfer tube bearing in the
tube bearing rear wall of the hopper.

" Shut the machine down.

" Disconnect the pump from the delivery line.

" Open the grille on the hopper and secure it.

" Attach suitable lifting gear to the S transfer tube.

" Remove the lubrication lines from the transfer tube bearing.

" Undo the nuts on the pressure flange.

" Remove the pressure flange and withdraw the pressure con

nection and the transfer tube bearing.

3 4
WK07_069_1109EN 1

No. 0 Designation
1 Hopper
2 Pressure connection
3 Pressure flange
4 Hexagon nuts

" Check the seal rings and O−rings in the transfer tube bearing
for wear and replace as required.

WK07_069_1109EN 575
 Maintenancecard
07−069
Page 4 of 6

Replacing the transfer

tube bearing gasket
set

WK07_069_1109EN 2

Bending the grooved ring to make installation easier

Caution
The mounting position for the gasket set in the transfer tube bearing
can be found in the corresponding spare parts sheet.

" Grease the new gasket set.

" Bend the grooved ring to make installation easier.

" Insert the gasket set as shown on the spare parts sheet.

Note
Clean the transfer tube bearing before refitting and grease the seals.
Check the lubricant bores, in particular, for proper functioning. This
is done by connecting the lubrication lines and forcing grease
through the openings.

576 WK07_069_1109EN
 Maintenancecard
07−069
Page 5 of 6

Fitting the transfer

tube bearing

WK07_069_1109EN 3

Note
Pay attention to the location of the lubrication openings when fitting
the transfer tube bearing.

" Fit the transfer tube bearing and the pressure connection again
and bolt them both in place with the pressure flange.

WK07_069_1109EN 577
 Maintenancecard
07−069
Page 6 of 6

578 WK07_069_1109EN
 Maintenancecard
07−070
Page 1 of 16

07–070 Replacing the switching This maintenance card describes how to replace the switching shaft
shaft bearing (flanged bearing (flanged bearing). You will find the maintenance intervals in
bearing) the maintenance summary at the start of this chapter.

Note
There are specific risks of an accident associated with maintenance,
inspection and repair work. For this reason, read the chapter "Safety
regulations" and the description of the "Residual risks during main
tenance, inspection and repair work" at the start of the chapter en
titled "Maintenance" (i.e. this chapter).

See also the maintenance cards:

Adjusting the S transfer tube

No special tools required.

MA The tightening torques can be found in the corresponding

Spareparts list.

Danger of crushing
A pressurized hydraulic system may cause the machine to move
suddenly, which may result in you being seriously injured if you are
working on the machine. To avoid risk, shut the machine down and
secure it against unauthorized or accidental starting.

Caution
Use only suitable lifting equipment for lifting components.

WK07_070_1109EN 579
 Maintenancecard
07−070
Page 2 of 16

Note
Wear parts must be replaced in the event of one of the following:
 Severe wear is visible
 Concrete is seeping out

When maintenance work is carried out, the machine must have been
shut down. The operations necessary for this task are described
below and must be carried out conscientiously. Perform all machine
functions using the remote control.

Shutting down the Proceed as follows to shut down the machine:

machine
" Switch off the engine.

" Dump the pressures completely.

Danger
Dump the accumulator pressure completely in systems with pressure
accumulators.

580 WK07_070_1109EN
 Maintenancecard
07−070
Page 3 of 16

Starting up the The machine may be started up differently depending on the ma

machine chine model. When you are starting up a truck−mounted concrete
pump, proceed as follows:

" Unlock the EMERGENCY STOP button and sound the horn.

" Switch the engine on.

Caution
Do not switch the pump on until you are called upon to do so.

When you are starting up a stationary concrete pump, proceed as

follows:

" If there is a throttle, set it to one third.

" Start up the engine.

" Select a low output.

" Switch the pump on.

WK07_070_1109EN 581
 Maintenancecard
07−070
Page 4 of 16

Overview
1 2 3 4 5 6 7 8 9 10 11

14 13 12
WK07_070_1109EN 1

No. 0 Designation
1 Pulling bore for ball cup
2 Ball cup
3 Hydraulic port
4 Plunger cylinder
5 Retaining plate
6 Retaining plate fastening bolts
7 Switch lever
8 Clamping bolts with nuts
9 Disc
10 Switching shaft
11 Hexagon nut
12 Flanged bearing
13 Pulling bore for flanged bearing (two diagonally opposite
each other)
14 Fastening bolt for flanged bearing (covered)

582 WK07_070_1109EN
 Maintenancecard
07−070
Page 5 of 16

Removing the switch- The switching shaft (10) of the S transfer tube is supported in the
ing shaft bearing flanged bearing (12) in the front wall of the hopper.
(flanged bearing)

" Shut the machine down.

" Remove any lubrication lines from the retaining plate(5) and
flanged bearing(12).

WK07_070_1109EN 2

Unbolting the retaining plate

" Screw the fastening bolts(6) out of the retaining plate(5) and
remove the retaining plate(5). (You will have to replace the
lock washers on the fastening bolts (6) with new ones on reas

sembly.)

WK07_070_1109EN 583
 Maintenancecard
07−070
Page 6 of 16

Environmental protection
All functional fluids and operating materials, e.g. oils (including bio
logically degradable oils), filters and auxiliary materials must be
carefully collected and disposed of separately, both from each other
and from other waste. Different categories of oil must also be kept
separately from each other. Nationally and regionally applicable dis
posal regulations must be observed for these materials.

" Place an oil sump pan under the working area.

" Place a container under the bulkhead union as well.

" Unscrew the hydraulic hose that leads to the plunger cylinder
from the bulkhead union.

" Catch the hydraulic fluid flowing out of the hydraulic line and
hydraulic hose.

" Seal the hydraulic line with a plug.

584 WK07_070_1109EN
 Maintenancecard
07−070
Page 7 of 16

1 2 3 4

WK07_070_1109EN 3

No. 0 Designation
1 Plunger cylinder
2 Locking plate
3 Ball cup
4 Pulling bore

Note
You can press a plunger cylinder(1) out of the ball cup(3) from the
piston side as shown. If the ball cup is worn, you can screw a bolt
into the pulling bore(4) for the ball cup and press out the plunger
cylinder with the ball cup.

" Remove the locking plate(2).

" Press the piston rod on the plunger cylinder(1) back.

" Catch the hydraulic fluid flowing out of the hydraulic hose.

" Remove the plunger cylinder(1) and hydraulic hose.

WK07_070_1109EN 585
 Maintenancecard
07−070
Page 8 of 16

" If required, remove the hydraulic hose from the plunger cylin

der(1).

" Remove the second plunger cylinder(1) in the same way.

" Unscrew the hexagon nut and remove it from the switching
shaft, and remove the washer.

Note
If the switch lever has a slot, this means that the switch lever is fitted
with clamping bolts, and a pulling bolt is also provided.

1 2 3

4 5 6
WK07_070_1109EN 4

No. 0 Designation
1 Clamping bolts
2 Switch lever
3 Slot
4 Pulling bolt
5 Holes for clamping bolts
6 Nuts for clamping bolts

586 WK07_070_1109EN
 Maintenancecard
07−070
Page 9 of 16

WK07_070_1109EN 5

Unscrew and remove the clamping bolts if the switch lever is

slotted

" If available, unscrew and remove the clamping bolts(1) from

the switch lever (2).

Note
One of the holes (5) for the clamping bolts(1) is also the pulling bore
for the switch lever(2).

" If required, force the switch lever(2) apart by turning the pul

ling bolt supplied(4) into the pulling bore.

" Pull the switch lever(2) from the switching shaft.

WK07_070_1109EN 587
 Maintenancecard
07−070
Page 10 of 16

1 2

WK07_070_1109EN 6

No. 0 Designation
1 Fastening bolt
2 Pulling bores (two, diagonally opposite each other)
3 Flanged bearing

" Unscrew the fastening bolt(1) from the flanged bearing (3).

" Attach suitable lifting gear to the S transfer tube.

" Press out the flanged bearing(3) by turning the two pulling
bolts supplied into the pulling bores(2).

" Check the gasket set on the flanged bearing for wear, and re

place the gasket set if required.

588 WK07_070_1109EN
 Maintenancecard
07−070
Page 11 of 16

Replacing the gasket

set in the flanged
bearing

WK07_070_1109EN 7

Removing the retaining ring

" Remove the retaining ring.

WK07_070_1109EN 8

Removing the old grooved ring

" Remove the old gasket set. To do this, you may have to cut
open the rings.

WK07_070_1109EN 589
 Maintenancecard
07−070
Page 12 of 16

WK07_070_1109EN 9

Inserting the new grooved ring

" Clean the flanged bearing.

" Grease the new gasket set.

Caution
For the mounting position of the grooved ring in the flanged bearing,
please refer to the accompanying spare parts sheet.

" Insert the gasket set.

" If there is a friction bearing bush, check it and replace if

necessary.

" Fit the retaining ring.

590 WK07_070_1109EN
 Maintenancecard
07−070
Page 13 of 16

Wear sleeve on
flanged bearing and
collared washer

1 2 3 4 5
WK07_070_1109EN 10

No. 0 Designation
1 Wear sleeve on the flanged bearing
2 Flanged bearing
3 Collared washer
4 Bore
5 Tab

" Bend the tab (5) on the collared washer(3) downwards.

" Place the collared washer(3) on the flanged bearing (2) so that
the tab (5) is located in the bore (4), thereby securing the
washer against rotation.

" Insert the wear sleeve(1) into the flanged bearing (2).

Note
Note the location of the lubrication bores when fitting the flanged
bearing (2).

" Grease the inside of the wear sleeve (1) with Anti−Seize AS
450 Assembly Paste" or an equivalent assembly grease.

" Locate the complete flanged bearing(2) on the switching shaft

and bolt the flanged bearing (2) in place.

WK07_070_1109EN 591
 Maintenancecard
07−070
Page 14 of 16

Mounting the switch

1 2 3 4 5
lever

7 6
WK07_070_1109EN 11

No. 0 Designation
1 Switch lever
2 Switching shaft
3 Switching shaft bearing (flanged bearing)
4 Groove
5 Wear sleeve
6 Flattened tooth
7 Notch

" Grease the teeth on the switch lever (1) and the switching shaft
(2) with Anti−Seize AS 450 assembly paste" or equivalent as

sembly grease.

" Fit the switch lever(1) so that the flattened tooth(6) on the
switching shaft(2) sits in the notch (7) on the switch lever(1).

" Fit the switch lever(1) on the switching shaft(2), so that the
switch lever(1) sits in the groove (4) on the wear sleeve(5).

592 WK07_070_1109EN
 Maintenancecard
07−070
Page 15 of 16

" Fit the washer to the switching shaft and screw the hexagon
nut onto the switching shaft.

" Lubricate the flanged bearing using the centralized lubrication

system / grease gun.

" Insert the plunger cylinder.

Note
The hydraulic system must be bled once assembly is complete if you
have removed the hydraulic hoses from the plunger cylinders. Do
this by starting up the pump slowly and switching the Stransfer tube
across slowly a few times.

" Adjust the S transfer tube so that it switches correctly.

Maintenance card: Adjusting the S transfer tube

WK07_070_1109EN 593
 Maintenancecard
07−070
Page 16 of 16

594 WK07_070_1109EN
 Maintenancecard
07−071
Page 1 of 14

07–071 Replace the spectacle wear This maintenance card describes how to replace the spectacle wear
plate plate. You will find the maintenance intervals in the maintenance
summary at the start of this chapter.

Note
There are specific risks of an accident associated with maintenance,
inspection and repair work. For this reason, read the chapter "Safety
regulations" and the description of the "Residual risks during main
tenance, inspection and repair work" at the start of the chapter en
titled "Maintenance" (i.e. this chapter).

See also the maintenance cards:

Replacing the transfer tube bearing
Replacing the switching shaft bearing (flanged bearing)
Replacing the thrust ring and wear ring
Adjusting the S transfer tube

You should request the special fitting instructions from us if you have
a spectacle wear plate made from a special material (e.g. hard
metal, hard cast iron, ceramics).

No special tools required.

MA The tightening torques can be found in the corresponding

Spareparts list.

WK07_071_1109EN 595
 Maintenancecard
07−071
Page 2 of 14

Danger of crushing
A pressurized hydraulic system may cause the machine to move
suddenly, which may result in you being seriously injured if you are
working on the machine. To avoid risk, shut the machine down and
secure it against unauthorized or accidental starting.

Caution
Use only suitable lifting equipment for lifting components.

Note
Wear parts must be replaced in the event of one of the following:
 Severe wear is visible
 Concrete is seeping out

596 WK07_071_1109EN
 Maintenancecard
07−071
Page 3 of 14

When maintenance work is carried out, the machine must have been
shut down. The operations necessary for this task are described
below and must be carried out conscientiously. Perform all machine
functions using the remote control.

Shutting down the Proceed as follows to shut down the machine:

machine
" Switch off the engine.

" Dump the pressures completely.

Danger
Dump the accumulator pressure completely in systems with pressure
accumulators.

Starting up the The machine may be started up differently depending on the ma

machine chine model. When you are starting up a truck−mounted concrete
pump, proceed as follows:

" Unlock the EMERGENCY STOP button and sound the horn.

" Switch the engine on.

Caution
Do not switch the pump on until you are called upon to do so.

When you are starting up a stationary concrete pump, proceed as

follows:

" If there is a throttle, set it to one third.

" Start up the engine.

" Select a low output.

" Switch the pump on.

WK07_071_1109EN 597
 Maintenancecard
07−071
Page 4 of 14

Overview
1 2 3 4 5 1

6 6 6
WK07_071_1109EN 1

No. 0 Designation
1 Plunger cylinder
2 Switch lever
3 Clamping bolts with nuts
4 Switching shaft
5 Hexagon nut
6 Fastening bolts for spectacle wear plate

598 WK07_071_1109EN
 Maintenancecard
07−071
Page 5 of 14

Removing the spec- The following describes how to remove the spectacle wear plate.
tacle wear plate
" Shut the machine down.

" Undo the hexagon nut(5) from the switching shaft(4), remove
the plunger cylinder(1) and undo the clamping bolts(3) on the
switch lever(2).
Maintenance card: Replacing the switching shaft bearing
(flanged bearing)

WK07_071_1109EN 2

Pushing the S transfer tube to one side

Note
If there is not enough space available for assembly, you can pull the
pressure connection towards the back.

" Push the S transfer tube away from the spectacle wear plate.

" Undo the eightfastening bolts (6) for the spectacle wear plate.

" Remove the spectacle wear plate from the hopper.

WK07_071_1109EN 599
 Maintenancecard
07−071
Page 6 of 14

Replacing the inter-

mediate rings

1 2 3 4 5

WK07_071_1109EN 3

No. 0 Designation
1 Transition liner
2 Intermediate ring
3 Screw plug
4 Lubrication nipples
5 Grease gun

5100 WK07_071_1109EN
 Maintenancecard
07−071
Page 7 of 14

" Using a plastic−faced hammer, strike the old intermediate

ring(2) several times to remove any grout residue that could
block the intermediate ring(2) when it is being removed.

" Replace the screw plug(3) on the underside of the transition

liner(1) using the lubrication nipple(4) from the accessories.

" Connect a grease gun(5) to the lubrication nipple(4).

" Keep pumping in grease until the intermediate ring(2) is

pressed out.

WK07_071_1109EN 4

Leave the bore open

" Remove the lubrication nipple(4) again.

å This will prevent an air cushion from being formed when the
new intermediate ring(2) is inserted, allowing you to insert the
intermediate ring(2) more easily.

" Clean the surface thoroughly. Remove all concrete and grout
residue.

WK07_071_1109EN 5101
 Maintenancecard
07−071
Page 8 of 14

1 2 3
WK07_071_1109EN 5

No. 0 Designation
1 Intermediate ring
2 O−rings
3 Transition liner

" Slide in two O−rings(2) over the mounting surface of the new
intermediate ring(1).

" Grease the mounting surface of the new intermediate ring(1).

" Insert the new intermediate ring(1) into the transition liner(3).

5102 WK07_071_1109EN
 Maintenancecard
07−071
Page 9 of 14

" Using a plastic−faced hammer, tap the intermediate ring(1)

fully into the transition liner(3).

" Replace the second intermediate ring(1) in the same way.

WK07_071_1109EN 6

Fitting the O−ring

" Insert one O−ring (2) into the recess at the front of the inter

mediate ring(1).

Fitting the spectacle The following describes how to insert the spectacle wear plate.
wear plate

" Fit the new spectacle wear plate.

WK07_071_1109EN 5103
 Maintenancecard
07−071
Page 10 of 14

1 1

2 3

ÉÉÉÉÉÉ
ÉÉÉÉÉÉ
ÉÉÉÉÉÉ
ÉÉÉÉÉÉ
4 5 6 7

WK07_071_1109EN 7

No. 0 Designation
1 Fastening bolts on the left and right
2 Spectacle wear plate
3 Fastening bolts at the top and bottom
4 Intermediate ring
5 O−ring
6 Hopper wall
7 Clearance

5104 WK07_071_1109EN
 Maintenancecard
07−071
Page 11 of 14

Caution
The spectacle wear plate(2) only touches the O−rings(5) in the in
termediate rings(4). There is a small gap (7) between the spectacle
wear plate(2) and hopper wall (6). For this reason, only tighten the
fastening bolts(1) on the left and right finger−tight at first, because
otherwise the spectacle wear plate(2) will be distorted.

" Fit the new spectacle wear plate(2).

" Using the fastening bolts on the left and right(1), screw on the
new spectacle wear plate(2) finger−tight.

Note
If you have a ceramic spectacle wear plate(2), please contact our
After Sales department to enquire about the tightening torques.

" Using the fastening bolts at the top and bottom (3), screw on
the spectacle wear plate(2) to the appropriate tightening
torque.

Caution
Take care to ensure that the spectacle wear plate(2) does not be
come distorted.

" Using the fastening bolts on the left and right (1), screw on the
spectacle wear plate(2) to the appropriate tightening torque.

WK07_071_1109EN 5105
 Maintenancecard
07−071
Page 12 of 14

WK07_071_1109EN 8

Close the fitting bore

Caution
The fitting bores must be closed to prevent any dirt penetration.

To seal the pulling bores, only use the screw plugs, and not the lu
brication nipples. Otherwise, there is a risk that you will accidentally
lubricate these lubrication nipples as well while lubricating the ma
chine. Over time, this would push out the intermediate rings, and the
spectacle wear plate would be distorted.

" After inserting the new intermediate rings and spectacle wear
plate, seal the pulling bores again using the screw plugs.

5106 WK07_071_1109EN
 Maintenancecard
07−071
Page 13 of 14

" Replace the thrust ring and wear ring.

Maintenance card: Replacing the thrust ring and wear ring

" Fit the transfer tube bearing.

Maintenance card: Replacing the transfer tube bearing

" Insert the plunger cylinder.

Maintenance card: Replacing the switching shaft bearing
(flanged bearing)

" Adjust the S transfer tube so that it switches correctly.

Maintenance card: Adjusting the S transfer tube

WK07_071_1109EN 5107
 Maintenancecard
07−071
Page 14 of 14

5108 WK07_071_1109EN
 Maintenancecard
07−072
Page 1 of 8

07–072 Replacing the This maintenance card describes how to replace the S transfer tube.
S transfer tube You will find the maintenance intervals in the maintenance summary
at the start of this chapter.

Note
There are specific risks of an accident associated with maintenance,
inspection and repair work. For this reason, read the chapter "Safety
regulations" and the description of the "Residual risks during main
tenance, inspection and repair work" at the start of the chapter en
titled "Maintenance" (i.e. this chapter).

See also the maintenance cards:

Replacing the transfer tube bearing
Replacing the switching shaft bearing (flanged bearing)
Replacing the S transfer tube wear sleeve
Replacing the thrust ring and wear ring
Adjusting the S transfer tube
Measuring the wall thickness
Measuring the wall thickness of the double−layer pipe

No special tools required.

MA The tightening torques can be found in the corresponding

Spareparts list.

WK07_072_1109EN 5109
 Maintenancecard
07−072
Page 2 of 8

Danger of crushing
A pressurized hydraulic system may cause the machine to move
suddenly, which may result in you being seriously injured if you are
working on the machine. To avoid risk, shut the machine down and
secure it against unauthorized or accidental starting.

Caution
Use only suitable lifting equipment for lifting components.

Note
Wear parts must be replaced in the event of one of the following:
 Severe wear is visible
 Concrete is seeping out

We recommend that the switch lever also be replaced when the S

transfer tube is replaced. Practical experience has shown that the
toothing on the switching shaft and that on the switch lever wear to
gether as a result of the forces generated during switchover. Dam
age may be caused by an imprecise fit if only one component is re
placed.

Maintenance card: Replacing the switching shaft bearing

(flanged bearing)

5110 WK07_072_1109EN
 Maintenancecard
07−072
Page 3 of 8

When maintenance work is carried out, the machine must have been
shut down. The operations necessary for this task are described
below and must be carried out conscientiously. Perform all machine
functions using the remote control.

Shutting down the Proceed as follows to shut down the machine:

machine
" Switch off the engine.

" Dump the pressures completely.

Danger
Dump the accumulator pressure completely in systems with pressure
accumulators.

Starting up the The machine may be started up differently depending on the ma

machine chine model. When you are starting up a truck−mounted concrete
pump, proceed as follows:

" Unlock the EMERGENCY STOP button and sound the horn.

" Switch the engine on.

Caution
Do not switch the pump on until you are called upon to do so.

When you are starting up a stationary concrete pump, proceed as

follows:

" If there is a throttle, set it to one third.

" Start up the engine.

" Select a low output.

" Switch the pump on.

WK07_072_1109EN 5111
 Maintenancecard
07−072
Page 4 of 8

S transfer tube vari-

ants

1 2

WK07_072_1109EN 1

No. 0 Designation
1 S transfer tube with bolted switching shaft
2 S transfer tube with welded switching shaft

Note
Whichever variant of S transfer tube is fitted, the recommended pro
cedure for dismantling is as described below. The S transfer tube
with bolted switching shaft may also be dismantled and reassembled
in the hopper. The tube is then dismantled as described in the
S
transfer tube with bolted switching shaft" maintenance card.

You should also consult the
Divided hopper" maintenance card if

your machine has a divided hopper.

5112 WK07_072_1109EN
 Maintenancecard
07−072
Page 5 of 8

Removing the S Replace the S transfer tube if the wall thickness has fallen below the
transfer tube minimum.

Maintenance card: Measuring the wall thickness

Maintenance card: Measuring the wall thickness of the double−

layer pipe

" Shut the machine down.

" Attach suitable lifting gear to the S transfer tube.

" Remove the transfer tube bearing.

Maintenance card: Replacing the transfer tube bearing

" Remove the switching shaft bearing (flanged bearing).

Maintenance card: Replacing the switching shaft bearing
(flanged bearing)

WK07_072_1109EN 2

Removing the mixer shaft

" Remove the mixer shaft.

WK07_072_1109EN 5113
 Maintenancecard
07−072
Page 6 of 8

WK07_072_1109EN 3

Lifting out the S transfer tube

" Unbolt the scratch bar from the bottom of the S transfer tube.

" Push the S transfer tube forwards until the transfer tube outlet
is free.

" Lift the S transfer tube outlet opening first upwards and out.

Note
If just the wear sleeve is heavily worn, you can also replace just the
wear sleeve and then refit the S transfer tube.

Maintenance card: Replacing the wear sleeve on the S transfer

tube

" Fit the new S transfer tube. To do this, proceed in the reverse
order to removal.

5114 WK07_072_1109EN
 Maintenancecard
07−072
Page 7 of 8

" Fit a new thrust ring and a new wear ring.

Maintenance card: Replacing the thrust ring and wear ring

" Fit the switching shaft bearing (flanged bearing).

Maintenance card: Replacing the switching shaft bearing
(flanged bearing)

" Fit the transfer tube bearing.

Maintenance card: Replacing the transfer tube bearing

" Adjust the S transfer tube so that it switches correctly.

Maintenance card: Adjusting the S transfer tube

WK07_072_1109EN 5115
 Maintenancecard
07−072
Page 8 of 8

5116 WK07_072_1109EN
 Maintenancecard
07−073
Page 1 of 8

07–073 Replacing the This maintenance card describes how to replace the wear sleeve on
S transfer tube wear sleeve the S transfer tube. You will find the maintenance intervals in the
maintenance summary at the start of this chapter.

Note
There are specific risks of an accident associated with maintenance,
inspection and repair work. For this reason, read the chapter "Safety
regulations" and the description of the "Residual risks during main
tenance, inspection and repair work" at the start of the chapter en
titled "Maintenance" (i.e. this chapter).

See also the maintenance cards:

Replacing the transfer tube bearing
Replacing the switching shaft bearing (flanged bearing)

No special tools required.

MA The tightening torques can be found in the corresponding

Spareparts list.

WK07_073_1109EN 5117
 Maintenancecard
07−073
Page 2 of 8

Danger of crushing
A pressurized hydraulic system may cause the machine to move
suddenly, which may result in you being seriously injured if you are
working on the machine. To avoid risk, shut the machine down and
secure it against unauthorized or accidental starting.

Caution
Use only suitable lifting equipment for lifting components.

Note
Wear parts must be replaced in the event of one of the following:
 Severe wear is visible
 Concrete is seeping out

5118 WK07_073_1109EN
 Maintenancecard
07−073
Page 3 of 8

When maintenance work is carried out, the machine must have been
shut down. The operations necessary for this task are described
below and must be carried out conscientiously. Perform all machine
functions using the remote control.

Shutting down the Proceed as follows to shut down the machine:

machine
" Switch off the engine.

" Dump the pressures completely.

Danger
Dump the accumulator pressure completely in systems with pressure
accumulators.

Starting up the The machine may be started up differently depending on the ma

machine chine model. When you are starting up a truck−mounted concrete
pump, proceed as follows:

" Unlock the EMERGENCY STOP button and sound the horn.

" Switch the engine on.

Caution
Do not switch the pump on until you are called upon to do so.

When you are starting up a stationary concrete pump, proceed as

follows:

" If there is a throttle, set it to one third.

" Start up the engine.

" Select a low output.

" Switch the pump on.

WK07_073_1109EN 5119
 Maintenancecard
07−073
Page 4 of 8

Removing the wear If just the wear sleeve is heavily worn, you can replace it without hav

sleeve ing to replace the S transfer tube. You do not have to remove the S
transfer tube to do this.

" Shut the machine down.

" Remove the transfer tube bearing.

Maintenance card: Replacing the transfer tube bearing

" Loosen the hexagon nut on the switching shaft and the clamp

ing bolts on the switch lever.
Maintenance card: Replacing the switching shaft bearing
(flanged bearing)

Danger
There is a risk of burning during heating and fitting of the new wear
sleeve. Use suitable protective equipment.

5120 WK07_073_1109EN
 Maintenancecard
07−073
Page 5 of 8

1 2 3
WK07_073_1109EN 1

No. 0 Designation
1 Welds
2 Tube outlet
3 Wear sleeve

Removal when the S If the S transfer tube has been fitted, proceed as follows:
transfer tube is fitted
" Weld a metal pin onto the wear sleeve.

Caution
When cutting open the welds, take care not to damage the S transfer
tube.

" Carefully cut open the welds (1) on the front face between the
S transfer tube outlet(2) and wear sleeve(3) using an angle
grinder.

" Heat up the wear sleeve(3) evenly to approx. 140°C.

WK07_073_1109EN 5121
 Maintenancecard
07−073
Page 6 of 8

" Using a hammer, strike the metal pin to release the wear
sleeve.

" Remove the wear sleeve(3).

Removal when the S If the S transfer tube has been removed, proceed as follows:
transfer tube has been
removed Caution
When cutting open the welds and wear sleeve, take care not to dam
age the S transfer tube.

" Carefully cut open the welds (1) on the front face between the
S transfer tube outlet(2) and wear sleeve(3) using an angle
grinder.

" Heat up the wear sleeve(3) evenly to approx. 140°C.

" Cut open the wear sleeve carefully using an angle grinder.

" Remove the wear sleeve(3).

5122 WK07_073_1109EN
 Maintenancecard
07−073
Page 7 of 8

Fitting a wear sleeve

1 2
WK07_073_1109EN 2

No. 0 Designation
1 Wear sleeve
2 Tube outlet

Note
The wear sleeve(1) is chrome−plated, and must not therefore be
heated unevenly or too intensively.

" Heat up the new wear sleeve(1) evenly to approx. 140_C.

" Place the heated wear sleeve(1) over the tube outlet (2) and
allow the wear sleeve(1) to cool.

" On the front face, evenly position four welds between the wear
sleeve(1) and tube outlet(2).

" Grind the four welds.

WK07_073_1109EN 5123
 Maintenancecard
07−073
Page 8 of 8

" Fit the transfer tube bearing.

Maintenance card: Replacing the transfer tube bearing

" Tighten the hexagon nut on the switching shaft and the clamp

ing bolts on the switch lever.
Maintenance card: Replacing the switching shaft bearing
(flanged bearing)

5124 WK07_073_1109EN
 Maintenancecard
07−074
Page 1 of 6

07–074 Replacing the thrust ring This maintenance card describes how to replace the thrust ring and
and wear ring wear ring on the S transfer tube. You will find the maintenance inter

vals in the maintenance summary at the start of this chapter.

Note
There are specific risks of an accident associated with maintenance,
inspection and repair work. For this reason, read the chapter "Safety
regulations" and the description of the "Residual risks during main
tenance, inspection and repair work" at the start of the chapter en
titled "Maintenance" (i.e. this chapter).

See also the maintenance cards:

Replacing the transfer tube bearing
Replacing the switching shaft bearing (flanged bearing)
Replacing the spectacle wear plate
Adjusting the S transfer tube

No special tools required.

MA The tightening torques can be found in the corresponding

Spareparts list.

WK07_074_1109EN 5125
 Maintenancecard
07−074
Page 2 of 6

Danger of crushing
A pressurized hydraulic system may cause the machine to move
suddenly, which may result in you being seriously injured if you are
working on the machine. To avoid risk, shut the machine down and
secure it against unauthorized or accidental starting.

Caution
Use only suitable lifting equipment for lifting components.

Note
Wear parts must be replaced in the event of one of the following:
 Severe wear is visible
 Concrete is seeping out

5126 WK07_074_1109EN
 Maintenancecard
07−074
Page 3 of 6

When maintenance work is carried out, the machine must have been
shut down. The operations necessary for this task are described
below and must be carried out conscientiously. Perform all machine
functions using the remote control.

Shutting down the Proceed as follows to shut down the machine:

machine
" Switch off the engine.

" Dump the pressures completely.

Danger
Dump the accumulator pressure completely in systems with pressure
accumulators.

Starting up the The machine may be started up differently depending on the ma

machine chine model. When you are starting up a truck−mounted concrete
pump, proceed as follows:

" Unlock the EMERGENCY STOP button and sound the horn.

" Switch the engine on.

Caution
Do not switch the pump on until you are called upon to do so.

When you are starting up a stationary concrete pump, proceed as

follows:

" If there is a throttle, set it to one third.

" Start up the engine.

" Select a low output.

" Switch the pump on.

WK07_074_1109EN 5127
 Maintenancecard
07−074
Page 4 of 6

Removing the thrust To remove the thrust ring and wear ring, proceed as follows:
ring and wear ring
" Shut the machine down.

" Remove the transfer tube bearing.

Maintenance card: Replacing the transfer tube bearing

" Loosen the hexagon nut on the switching shaft and the clamp

ing bolts on the switch lever.
Maintenance card: Replacing the switching shaft bearing
(flanged bearing)

" Inspect the spectacle wear plate and replace it if required.

Maintenance card: Replacing the spectacle wear plate

5128 WK07_074_1109EN
 Maintenancecard
07−074
Page 5 of 6

1 2
WK07_074_1109EN 1

No. 0 Designation
1 Thrust ring
2 Wear ring

" Remove the old wear ring (2) and the old thrust ring (1).

Fitting the thrust ring To fit the thrust ring and wear ring, proceed as follows:
and wear ring
" Clean the thrust ring seat (1) thoroughly. Dirt and concrete resi

due must be removed from the seat.

" Fit the new thrust ring (1) and new wear ring (2) into the S
transfer tube.

" Fit the transfer tube bearing.

Maintenance card: Replacing the transfer tube bearing

" Adjust the S transfer tube so that it switches correctly.

Maintenance card: Adjusting the S transfer tube

WK07_074_1109EN 5129
 Maintenancecard
07−074
Page 6 of 6

5130 WK07_074_1109EN
 Maintenancecard
07−075
Page 1 of 14

07–075 Adjusting the This maintenance card describes how to adjust the S transfer tube.
S transfer tube This includes:
− prestressing the S transfer tube and
− adjusting the switching overlap between the wear ring and spec

tacle wear plate on the S transfer tube.

Note
There are specific risks of an accident associated with maintenance,
inspection and repair work. For this reason, read the chapter "Safety
regulations" and the description of the "Residual risks during main
tenance, inspection and repair work" at the start of the chapter en
titled "Maintenance" (i.e. this chapter).

See also the maintenance cards:

Replacing the switching shaft bearing (flanged bearing)

No special tools required.

MA The tightening torques can be found in the corresponding

Spareparts list.

WK07_075_1109EN 5131
 Maintenancecard
07−075
Page 2 of 14

Danger of crushing
A pressurized hydraulic system may cause the machine to move
suddenly, which may result in you being seriously injured if you are
working on the machine. To avoid risk, shut the machine down and
secure it against unauthorized or accidental starting.

Caution
Use only suitable lifting equipment for lifting components.

Note
Wear parts must be replaced in the event of one of the following:
 Severe wear is visible
 Concrete is seeping out

5132 WK07_075_1109EN
 Maintenancecard
07−075
Page 3 of 14

You will have to shut down and restart the machine a number of
times. The operations necessary for this task are described below
and must be carried out conscientiously. Perform all machine func

tions using the remote control.

Shutting down the Proceed as follows to shut down the machine:

machine
" Switch off the engine.

" Dump the pressures completely.

Danger
Dump the accumulator pressure completely in systems with pressure
accumulators.

Starting up the The machine may be started up differently depending on the ma

machine chine model. When you are starting up a truck−mounted concrete
pump, proceed as follows:

" Unlock the EMERGENCY STOP button and sound the horn.

" Switch the engine on.

Caution
Do not switch the pump on until you are called upon to do so.

When you are starting up a stationary concrete pump, proceed as

follows:

" If there is a throttle, set it to one third.

" Start up the engine.

" Select a low output.

" Switch the pump on.

WK07_075_1109EN 5133
 Maintenancecard
07−075
Page 4 of 14

Prestressing the S First, prestress the S transfer tube.

transfer tube
" Shut the machine down.

5 6 7 8

1 2 3 4
WK07_075_1109EN 1

No. 0 Designation
1 Spectacle wear plate
2 Wear ring
3 S transfer tube
4 Thrust ring
5 Gap
6 Hexagon nut
7 Retaining plate
8 Switch lever
9 Clamping bolts

Note
Make sure that the thrust ring (4) is not damaged when it is pressed
in.

" Unscrew the clamping bolts(9) from the switch lever(8).

5134 WK07_075_1109EN
 Maintenancecard
07−075
Page 5 of 14

" Tighten the hexagon nut(6) on the switching shaft so that the
wear ring(2) lies flat against the spectacle wear plate(1).

Note
A gap (5) must be maintained between the S transfer tube(3) and
wear ring(2) so that the S transfer tube(3) switches correctly.

" Check that the wear ring (2) makes contact with the spectacle
wear plate (1) on all sides.

" Slowly tighten the hexagon nut(6) by half a turn.

å The thrust ring (4) is then compressed by 1.5mm.
å The gap (5) between the S transfer tube(3) and wear
ring(2) is set.

" Ensure that one surface on the hexagon nut(6) is horizontal at

the top so that the retaining plate(7) can be refitted.

" Fit the retaining plate(7).

Note
Use only new nuts for the clamping bolts (9).

" Insert the clamping bolts (9) into the switch lever (8) and fit
new nuts.

" Tighten the clamping bolts(9) to the required torque.

" Further assembly is carried out in the reverse sequence to dis

assembly.
Maintenance card: Replacing the switching shaft bearing
(flanged bearing)

" Check that all covers and other safety equipment have been
refitted and are fully functional.

WK07_075_1109EN 5135
 Maintenancecard
07−075
Page 6 of 14

Setting the switching The switching overlap is set to the optimum if the wear ring is central
overlap to the relevant hole in the spectacle wear plate for both switch posi

tions of the S transfer tube. In other words, the swing angle of the S
transfer tube must not be either too great or too small.

Spectacle wear plate

with wear ring
1 2

WK07_075_1109EN 2

No. 0 Designation
1 Swing angle too great
2 Swing angle too small
3 Optimum swing angle

The left−hand switching overlap is corrected by replacing the pack

ing washer behind the ball cup on the right−hand plunger cylinder
with a thicker or thinner one as required. The right−hand switching
overlap is corrected on the left in the same way.

5136 WK07_075_1109EN
 Maintenancecard
07−075
Page 7 of 14

1 2 3

WK07_075_1109EN 3

No. 0 Designation
1 Plunger cylinder
2 Ball cup
3 Packing washer

" Start the machine up.

WK07_075_1109EN 4

Plunger cylinder extended

" Allow one plunger cylinder to retract completely.

" Shut the machine down.

WK07_075_1109EN 5137
 Maintenancecard
07−075
Page 8 of 14

WK07_075_1109EN 5

No. 0 Designation
1 Marking the spectacle wear plate

" Use a felt tip pen or oil chalk to mark the position of the wear
ring on the spectacle wear plate.

" Start the machine up.

" Allow the other plunger cylinder to retract.

" Shut the machine down.

" Determine to which side and by how many millimetres the

circle you have drawn is offset against the circle of the spec

tacle wear plate.

5138 WK07_075_1109EN
 Maintenancecard
07−075
Page 9 of 14

Spectacle wear plate

with sample markings

1 2

WK07_075_1109EN 6

No. 0 Designation
1 Packing washer too thin
2 Packing washer too thick
3 Optimum packing washer

To decrease the swing angle of the Stransfer tube by 4mm, the

fitted packing washer must be replaced by one which is 2mm
thicker.
To increase the swing angle of the Stransfer tube by 4mm, the fitted
packing washer must be replaced by one which is 2mm thinner.

WK07_075_1109EN 5139
 Maintenancecard
07−075
Page 10 of 14

1 2

WK07_075_1109EN 7

No. 0 Designation
1 Plunger cylinder
2 Locking plate

" Remove the locking plate(2) of the extended plunger cylin

der(1).

10300800

Removing the plunger cylinders

Note
The plunger cylinders can be pushed back as illustrated. It is, how
ever, also possible to screw a bolt into the jacking bores for the ball
cups and to push the plunger cylinders out with the ball cups.

5140 WK07_075_1109EN
 Maintenancecard
07−075
Page 11 of 14

" Force the piston of the extended plunger cylinder back a little
and remove the plunger cylinder with the hydraulic hoses.

1 2

WK07_075_1109EN 8

No. 0 Designation
1 Ball cup
2 Packing washer

" Remove the hexagon ball cup (1) along with the packing
washer (2).

Caution
No packing washers (2) may be inserted in the switch lever, as other
wise the plunger cylinder can run over the edge of the ball cup (1)
and break it.

" As required, fit a thicker or thinner packing washer (2) with the
ball cup (1).

" Fit the plunger cylinder and locking plate.

" Start the machine up.

WK07_075_1109EN 5141
 Maintenancecard
07−075
Page 12 of 14

" Allow the Stransfer tube to switch over a few times. Stoppen
Sie, wenn die S−Rohrweiche auf der noch nicht markierten Bril

lenplattenseite steht.

" Shut the machine down.

" Check the switching overlap of the other side of the spectacle
wear plate and correct accordingly.

Switching overlap on The two plunger cylinders must extend to the same extent on ma

VHS control chines with fully hydraulic control (VHS) and active signal tapping in
the plunger cylinders.

20300703

Plunger cylinder extended

" First set a switching overlap of the wear ring and the spectacle
wear plate.

" Allow the plunger cylinder (1) to extend to its end position.

" Shut the machine down.

" Measure how far the plunger cylinder has extended. (Measure

ment E1)

" Start the machine up.

5142 WK07_075_1109EN
 Maintenancecard
07−075
Page 13 of 14

" Allow the plunger cylinder (2) to extend to its end position.

" Shut the machine down.

" Measure how far the plunger cylinder has extended. (Measure

ment E2)

" Compare the two measurements.

The two measurements E1 and E2 should be identical. You will have

to change the packing washers as described below if the two
measurements are not equal:

" Swap the packing washer on the plunger cylinder with the
greater measurement for a washer (E1−E2):2 thinner.

" Swap the packing washer on the plunger cylinder with the
smaller measurement for a washer (E1−E2):2 thicker.

Note
This setting must be checked after a running−in period of approxi
mately 100 operating hours.

WK07_075_1109EN 5143
 Maintenancecard
07−075
Page 14 of 14

5144 WK07_075_1109EN
 Maintenancecard
08−007
Page 1 of 2

08–007 Lubrication This maintenance card describes how to lubricate the machine. The
machine is lubricated through a centralized lubrication nipple strip.
The lower bearings of the switch cylinders must also be lubricated.
All lubrication nipples must be lubricated once a day.

Hinweis
There are specific risks of an accident associated with maintenance,
inspection and repair work.
For this reason, read the chapter "Safetyregulations" and the
description of the "Residual risks during maintenance, inspection
and repair work" at the start of the chapter entitled "Maintenance"
(i.e. this chapter).

No further maintenance cards required.

The following special tools are required:

Grease gun

Hinweis
Use only those lubricants listed in the lubricant recommendation
table.

WK08_007_1109EN 5145
 Maintenancecard
08−007
Page 2 of 2

1 2

WK08_007_1109EN 1

1 Plate indicating the lubrication intervals

2 Centralized lubrication nipple strip
3 Lubrication nipple for the lower bearings on the switch cylinder

" Lubricate each lubrication nipple with a grease gun until clean
grease exits from the lubrication point.

Hinweis
The lubrication interval is specified for normal operation. More fre
quent lubrication may be necessary under extreme conditions.

5146 WK08_007_1109EN
 Maintenancecard
10−007
Page 1 of 6

10–007 Measuring the wall thick- This maintenance card describes how to measure the wall thickness
ness (Machines with of delivery lines. You will find the maintenance intervals in the main

S transfer tube) tenance summary at the start of this chapter.

Note
There are specific risks of an accident associated with maintenance,
inspection and repair work. For this reason, read the chapter "Safety
regulations" and the description of the "Residual risks during main
tenance, inspection and repair work" at the start of the chapter en
titled "Maintenance" (i.e. this chapter).

No further maintenance cards required.

The following special tools are required:

Wall thickness measuring device

MA The tightening torques can be found in the corresponding

Spareparts list.

WK10_007_1109EN 5147
 Maintenancecard
10−007
Page 2 of 6

Note
Delivery lines are subject to constant wear. Measurement of the wall
thickness is particularly important before starting on large jobs.
You will obtain reliable results for your measurements if you carry out
the test with the measuring device recommended by Putzmeister.

Danger of explosion
The delivery line can burst once it reaches a high delivery pressure if
the wall thickness of the delivery line has decreased below the mini
mum required, particularly if a blockage has built up.

5148 WK10_007_1109EN
 Maintenancecard
10−007
Page 3 of 6

Caution
Only tap the delivery line with a piece of hardwood (hammer handle).
Otherwise, dents may be created and these will lead to more rapid
wear. In addition, the hardened lining of high wear resisting pipes
may flake off the inside of the pipe. The pipe can burst at points that
have suffered heavy wear.

11000101

Tapping the delivery line with a hammer handle

Straight pipes Uniform wear can be achieved by regularly rotating the straight de

livery pipes through 120°.
The minimum wall thickness for straight pipes is shown in the graph
below.

Bends Uniform wear can be achieved by regularly rotating the bends

through 180°. The wear on the external radius of a bend is greater
than that on the internal radius or on straight pipes. You should,
therefore, take special care when measuring the wall thickness of the
external radius of a bend.
The minimum wall thickness for bends is shown in the graph below.

11000200

Rotate delivery pipes and bends regularly

WK10_007_1109EN 5149
 Maintenancecard
10−007
Page 4 of 6

S transfer tube The minimum wall thickness for the S transfer tube depends on the
maximum possible operating pressure. Furthermore, the fact that the
S transfer tube is subject to greater stress at the point at which the
torque is applied (switching shaft − S transfer tube) must be taken
into consideration.

WK10_007_1109EN 1

X = Area of heavy loading

Operating pressure up to Guide value for wall thick-

130 bar ness

AreaA 8−10mm
AreaB 6−8mm

Note
We should draw your attention to the fact that the S transfer tube is
subject to varying loading as a result of the dynamic loading during
pumping. There is no general method for calculating the minimum
wall thickness for this loading, which depends on the individual cir
cumstances, and so the S transfer tube can also burst at an operat
ing pressure which is assumed still to be permissible.

You should also note that the operating pressure can rise to the
maximum pressure in the event of a blockage, and in this case the
wall thickness may no longer be adequate.

If the operating pressure is higher than 130bar, you must ask

Putzmeister what the minimum wall thickness is.

5150 WK10_007_1109EN
 Maintenancecard
10−007
Page 5 of 6

Measuring Follow the Operating Instructions supplied with the measuring de

vice when carrying out measurements. Do not measure the wall
thickness of the delivery line at just one point, but around the entire
circumference of the delivery pipes.
The minimum wall thickness is shown in the graph below.

Caution
Pipes and bends must be replaced as soon as the wall thickness
has declined to the value for the minimum wall thickness.
Putzmeister accepts no liability if the wall thickness is less than the
minimum wall thickness.

Note
As a rule it is possible to continue pumping with an operating pres
sure lower than that shown in the graph.

We should, however, draw your attention to the fact that the delivery
line is subject to varying loading as a result of the dynamic loading
during pumping. There is no general method for calculating the mini
mum wall thickness for this loading, which depends on the individual
circumstances, and so the delivery line can also burst at an operat
ing pressure which is assumed still to be permissible.

Furthermore, the operating pressure can rise to 85 bar in the event of

blockages, meaning that the wall thickness will no longer be ad
equate and the delivery line will burst.

WK10_007_1109EN 5151
 Maintenancecard
10−007
Page 6 of 6

Graph Minimum wall thickness as a function of operating pressure

1 High pressure
2 Maximum delivery pressure

5152 WK10_007_1109EN
 Maintenancecard
10−044
Page 1 of 2

10–044 Measuring the wall thick- This maintenance card describes how to measure the wall thickness
ness of two–layer pipes of two−layer delivery lines.

Note
There are specific risks of an accident associated with maintenance,
inspection and repair work.
For this reason, read the chapter "Safetyregulations" and the
description of the "Residual risks during maintenance, inspection
and repair work" at the start of the chapter entitled "Maintenance"
(i.e. this chapter).

See also the maintenance cards:

Measuring the wall thickness

The following special tools are required:

Wall thickness measuring device, material no. 454460

Note
Observe all safety instructions in the machine−specific Operating
Instructions and in the Safety manual.

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

WK10_044_1109EN 5153
 Maintenancecard
10−044
Page 2 of 2

Inspecting two–layer Inspect two−layer delivery pipes and delivery line elbows
delivery pipes and (DN125,max. concrete pressure 85 bar) as follows:
delivery line elbows
" Visual inspection for cracks. Replace in case of crack
formation.

" Measure the wall thickness at the measuring points P1 and P 2.

Replace if the wall thickness has fallen below the minimum
required (see table).

Type Minimum (mm)

No. DN 125
P1 P2
up to 85 bar
Twin Pipe Twin Cast
1.1 7.1 + 3.6 4.1 3.6
Delivery line elbow
1.2 7.0 + 2.0 7.0 3.0
2.1 2.5 + 2.0 2.5 3.3
2.2 2.5 + 2.0 2.5 4.9
Delivery pipe
2.3 5.6 + 3.0 3.7 3.7
2.4 5.6 + 3.0 3.7 3.1

1.1 – 1.2
Delivery line elbow
Measuring points
P1/P2
Minimum (seetable)

2.1 – 2.4
Delivery pipe
Measuring points
P1/P2
Minimum (seetable)

Extract from Esser Service Manual – EM 070190, see Technical Appendix

5154 WK10_044_1109EN
 Indexofkeywords

6 Index of key words

In this section you will find the most important key words with the
number of the page on which you will find the key word as a heading
in the left margin. This Index of key words is listed alphabetically by
the main concepts. These are subdivided into associated sub−con

cepts, marked with a dash.

6—I
 Indexofkeywords

6 — II
 Indexofkeywords

Diesel Exhaust Fluid (DEF) delivery Hydraulic hoses, 2
10

A pump filter change, Maintenance
Maintenance, 5
41
Accumulator dump valve, Emergency card, 5
59
Hydraulic systems, 2
9
operation, 4
6 Disposal, Machine, 2
12
Agitator, Emergency operation, 4
3
I
Agitator emergency operation, 4
3 E
Agitator gearbox, Transmission oil, Icons, 1
3
Electrical components, 2
8
5
20 Intermediate rings on the transition
Agitator safety cutout Electrical power, 2
7 liner, Replacing, 5
100

Acknowledge, 3
11
Power at the construction site, 2
8
Emergency control levers, Delivery

Checking the safety function, 3
7

Description of the functions, 3
8 cylinder, 4
1 L

Function check, 3
9 Emergency operation Liability, Exclusion, 2
1

Unexpected restart, 3
11
Agitator, 4
3 Lubricant analysis, 5
15, 5
17
APP, Automatic Piston Pull, 5
63
Delivery cylinder, 4
6
Lubricant recommendation

Transfer tube, 4
6
Automatic Piston Pull, APP, 5
63
Agitator gearbox, 5
20
EMERGENCY STOP function
Engine oil, 5
20

Checking the safety function, 3
5
General, 5
18
C
Description of the functions, 3
5
Greases, 5
21

Function check, 3
6
Hydraulic fluids, 5
22
Centralized lubrication system

Grease, 5
21 Exhaust fumes, 2
11
Low temperature grease, 5
21

Low temperature grease, 5
21
Oils, 5
20

Pump tube grease, 5
21
Change-over valve, Transfer tube, 4
1 F
Rotor gearbox, 5
20
Components
Slewing gear transmission, 5
20
Faults, Recovering the machine, 4
5

Electrical components, 2
8
Transfer gearbox, 5
20

Safety
relevant components, 2
5 Filter change

Transmission oil, 5
20

Pressure filter, 5
53
Control devices Lubrication, Grease, 5
21

Suction filter, 5
47

Accumulator dump valve, 4
6

Agitator valve, 4
3 Flanged bearing, Replacing, 5
79

Delivery cylinder emergency control Flared screwed joint, 5
11 M
lever, 4
1
Fluid drain cock, 5
37 Maintenance and special work, 2
2

Emergency operation − transfer tube,
4
6 Fumes Maintenance cards

Emergency operation  delivery cylin

Exhaust, 2
11
Adjusting the S transfer tube, 5
131
der, 4
6
Noise, 2
10
Changing the hydraulic fluid, 5
37

Pump control system, 4
1, 4
6 Function checks, 5
27
Changing the pressure filter element,

Transfer tube change−over valve, 4
1 Functional fluids, 2
11, 5
15 5
53
Copyright, 1
2
Changing the suction filter element,
5
47
G
Checking the accumulator, 5
29
D Grille

DEF delivery pump filter change, 5
59

Delivery piston replacement, 5
63
Delivery cylinder, Emergency opera-
Checking the safety function, 3
14
Function checks, 5
27
tion, 4
6
Description of the functions, 3
14
Hydraulic hoses, 5
41
Delivery line
Function check, 3
15
Lubrication, 5
145

Measuring the wall thickness, 5
153
Measuring the wall thickness, 5
153

Measuring the wall thickness (Machi

nes with S transfer tube), 5
147 H
Measuring the wall thickness (Machi

nes with S transfer tube), 5
147
Delivery piston, Piston replacement, Hydraulic fluid
Replace the spectacle wear plate,
5
63
Fluid drain cock, 5
37 5
95

Full fluid change, 5
37
Replacing the S transfer tube, 5
109

i
 Indexofkeywords

Replacing the S transfer tube wear
WALFORMplus threaded union, 5
12

sleeve, 5
117 S Transfer gearbox, Transmission oil,

Replacing the switching shaft bearing S transfer tube 5
20
(flanged bearing), 5
79
Adjusting, 5
131 Transfer tube, Emergency operation,

Replacing the thrust ring and wear
Measuring the wall thickness, 5
147 4
6
ring, 5
125

Prestressing, 5
134

Replacing the transfer tube bearing, Transfer tube bearing, Replacing,

Replacing, 5
109 5
73
5
73

Switching overlap, 5
136

Vacuum meter, 5
45 Transfer tube change–over valve, 4
1

Visual checks, 5
25 S transfer tube wear sleeve, Repla-
cing, 5
117 Transition liner, Replacing the inter-
Measuring the wall thickness, 5
153 mediate rings, 5
100

Machines with S transfer tube, 5
147 Safety components, 3
4
Transmission oil
Safety equipment, 2
6
Agitator gearbox, 5
20

Active safety functions, 3
1
N
Overview, 3
1

Rotor gearbox, 5
20

Slewing gear transmission, 5
20

Passive safety functions, 3
1
Noise emissions, 2
10
Transfer gearbox, 5
20

Plates, 3
16
Two–layer delivery line elbow, Inspec-

Safety−related parts (SRPs), 3
2
tion, 5
154
O
Separating protective devices, 3
12
Two–layer delivery pipe, Inspection,
Safety functions
Organizational measures, Plates, 3
1, 5
154

Active, 3
1
3
16

Agitator safety cutout, 3
7

EMERGENCY STOP function, 3
5 U
P
Grille, 3
14
Unexpected restart, Agitator safety

Passive, 3
1
Parts with increased maintenance re-
Separating protective devices, 3
12 cutout, 3
11
quirements, 3
4
Safety regulations
Placing boom, Working on the pla-
cing boom, 2
5

Basic principle, 2
1 V

Exclusion of liability, 2
1
Plates, Inspection, 3
16 Vacuum meter, Venting, 5
45
Safety–related parts (SRPs), 3
2
Power, 2
8 Visual checks, 5
25
Safety-relevant components, 2
5
Power at the construction site, 2
8
Separating protective devices, 3
12
Profiled ring joint, 5
11
Slewing gear transmission, Transmis- W
Protective devices, Grille, 3
14 sion oil, 5
20
WALFORMplus threaded union, 5
12
Protective equipment, 2
6 Software, 2
6
Wear ring, Replacing, 5
125
Pump control system, 4
1 Special work, 2
2
Welding, 2
4

Emergency operation, 4
6 Spectacle wear plate, Replacing, 5
95
Pump tube in rotor pumps, Grease, SRP, 3
2
5
21
Switching shaft bearing, Replacing,
5
79
R Symbols, 1
3
Recovering the machine, 4
5

With on−board equipment, 4
6 T
Rotor gearbox, Transmission oil, 5
20
Thrust ring, Replacing, 5
125
Rotor pumps, Pump tube grease,
5
21 Tightening torques

Flared screwed joint, 5
11

General, 5
10

Profiled ring joint, 5
11

Set screws and nuts, 5
10

ii