Waitzinger THP 94/42 R 4 XXT User Manual
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Waitzinger THP 94/42 R 4 XXT User Manual

Concrete pump
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Waitzinger
Baumaschinen GmbH
User manual
WAITZINGER CONCRETE PUMP
THP 94/42 R 4 XXT
THP 125/42 R 4 XXT
THP 140 H/42 R 4 XXT

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Summary of Contents for Waitzinger THP 94/42 R 4 XXT

  • Page 1 Waitzinger Baumaschinen GmbH User manual WAITZINGER CONCRETE PUMP THP 94/42 R 4 XXT THP 125/42 R 4 XXT THP 140 H/42 R 4 XXT...
  • Page 2 © Waitzinger Baumaschinen GmbH. All rights reserved. This user manual is copyright to Waitzinger Baumaschinen GmbH. This document contains instructions and technical drawings and may therefore not be copied and released to third parties in whole or in part. Errors and omissions excepted.

  • Page 3: Table Of Contents

    Actions after contacting a high-tension overhead cable ......2-21 THP 94/42 R 4 XXT THP 125/42 R 4 XXT GB-07.2005...

  • Page 4: Contents

    Surplus concrete discharge opening ..........THP 94/42 R 4 XXT THP 125/42 R 4 XXT GB-07.2005...
  • Page 5 7.5.3 “Pump/Suck” control at the radio remote control / cable remote control ....7-17 THP 94/42 R 4 XXT THP 125/42 R 4 XXT GB-07.2005...
  • Page 6 Oils and greases ............THP 94/42 R 4 XXT THP 125/42 R 4 XXT GB-07.2005...
  • Page 7 Exchanging the wear plate and wear ring ......... 9-29 THP 94/42 R 4 XXT THP 125/42 R 4 XXT GB-07.2005...
  • Page 8 Maintenance and modifications list ..........12-1 THP 94/42 R 4 XXT THP 125/42 R 4 XXT GB-07.2005...

  • Page 9: Foreword

    If maintenance work is neglected or improperly performed, we may no longer be liable to perform our warranty obligations under our conditions of supply. Only original WAITZINGER spare parts ensure quality and interchangeability. NOTE: Safety instructions should be complied with at all times!

  • Page 11: Safety Instructions And Information

    After the machine has been delivered, check the completeness of the scope of supply against the delivery note. If anything is missing, or damage has occurred in transport, please report this immediately to WAITZINGER. The machine as delivered is in accordance with current technology and complies with the mandatory safety standards.
  • Page 12 WAITZINGER from any liability for direct or consequential damages such as personal injuries, damage to property not covered by the contract, loss of profits and interruption to production that comes under the heading “Product liability“...

  • Page 13: Safety Symbols

    These notes assist in making the best use of the functions of the machine / equipment. This symbol follows the text to which it relates. THP 94/42 R 4 XXT THP 125/42 R 4 XXT GB-07.2005 THP 140 H/42 R 4 XXT...

  • Page 14: Safety Equipment

    EN 292 “Safety of machines, equipment and systems” EN 60204-1 “Safety of machines; electrical equipment for industrial machines” EMC “Electromagnetic compatibility - Directive 89/336/EWG” THP 94/42 R 4 XXT THP 125/42 R 4 XXT GB-07.2005 THP 140 H/42 R 4 XXT...
  • Page 15 EC directive EN 60204-1 “Electrical equipment of machines, part 1” EG directive 73/23 “Insulation of cables” EG directive “Electromagnetic compatibility EMC” EG directive 92/58 “Personal safety equipment” EG directive 89/689 “Waste disposal” THP 94/42 R 4 XXT THP 125/42 R 4 XXT GB-07.2005 THP 140 H/42 R 4 XXT...

  • Page 16: Information On Risks Of Injury

    Injuries due to falling pipes. Injuries to personnel due to inadvertent operation of the machine controls and hence inadvertent operation of the machine. THP 94/42 R 4 XXT THP 125/42 R 4 XXT GB-07.2005 THP 140 H/42 R 4 XXT...
  • Page 17 Injuries due to unsecured conveying pipes slipping down or falling down. Risk of crushing at the complete outriggers. Injuries due to unintended movement of the distributor boom following inadvertent operation of the controls. THP 94/42 R 4 XXT THP 125/42 R 4 XXT GB-07.2005...

  • Page 18: Safety Information For Setting Up

    The operator must continually monitor the hazard area! The outriggers must not be extended when personnel are in their area of movement. Interlock the outriggers hydraulically or mechanically. THP 94/42 R 4 XXT THP 125/42 R 4 XXT GB-07.2005 THP 140 H/42 R 4 XXT...

  • Page 19: Setting Up

    .......... = 60° c. on rock ................. = 80° Fig. 2.4 Safety distances to the edges of excavation pits THP 94/42 R 4 XXT THP 125/42 R 4 XXT GB-07.2005 THP 140 H/42 R 4 XXT...

  • Page 20: Underground

    30 (3,0) 4. Rock, unweathered with little fissuring and in a good position 150-300 (15-30) Fig. 2.6 Premissible ground pressures for various types of ground THP 94/42 R 4 XXT THP 125/42 R 4 XXT 2-10 GB-07.2005 THP 140 H/42 R 4 XXT...

  • Page 21: Safety Instructions For Remote Control

    (e.g. limit switches or mechanical catches for the grill interlocks). Whilst the pump is running, keep off the machine. All operation should be by remote control only. THP 94/42 R 4 XXT THP 125/42 R 4 XXT 2-11 GB-07.2005...

  • Page 22: Distributor Boom

    The conveying pipes must be aligned so as to avoid kinks, sharp bends and damage in operation. THP 94/42 R 4 XXT THP 125/42 R 4 XXT 2-12 GB-07.2005...

  • Page 23: Locking The Conveying Pipe Connections

    AFETY INSTRUCTIONS AND INFORMATION HAPTER If worn or defective components (high pressure hoses etc.) are not immediately replaced, WAITZINGER will not accept product liability. Conveying pipes are not under stress when the distributor boom is stowed, and can thus be replaced without problems at that time. If conveying pipes are replaced when the distributor boom is deployed, stresses may be introduced during assembly.

  • Page 24: Discharge Hose

    There is an injury risk of being struck by the discharge hose or by stones shooting out of it. Hazard area = 2 x discharge hose length Fig. 2.9 Hazard area for the discharge hose THP 94/42 R 4 XXT THP 125/42 R 4 XXT 2-14 GB-07.2005...

  • Page 25: Kinks In The Discharge Hose

    • Always secure the discharge hose with the catch Boom element D Coupling Safety chain Clamp Discharge hose Fig. 2.12 Securing the discharge hose with the catch THP 94/42 R 4 XXT THP 125/42 R 4 XXT 2-15 GB-07.2005 THP 140 H/42 R 4 XXT...

  • Page 26: Agitator

    Take out the ignition key. Factory-set chokes and pressure limiting devices may not be adjusted except by trained technical staff. Removing the seals from safety valves is prohibited. THP 94/42 R 4 XXT THP 125/42 R 4 XXT 2-16 GB-07.2005...

  • Page 27: High Tension Overhead Electric Cables

    If any component is removed, carefully note how it was fitted and replace it correctly referring to the spare parts data sheet / service information. 2.12 High-tension overhead electric cables Fig. 2.13 Safety distances to high-tension overhead electric cables THP 94/42 R 4 XXT THP 125/42 R 4 XXT 2-17 GB-07.2005 THP 140 H/42 R 4 XXT...

  • Page 28: Safety Distance

    High ambient humidities require safety distances greater than those listed. Refer to the regulations for the country where the machine is in use. THP 94/42 R 4 XXT THP 125/42 R 4 XXT 2-18 GB-07.2005...

  • Page 29: High-Tension Contacts

    Electrical supply systems are equipped with automatic reconnection. After the switchgear has tripped, the short-circuited cable is automatically reconnected after a brief interval. It is therefore necessary to arrange permanent disconnection. THP 94/42 R 4 XXT THP 125/42 R 4 XXT 2-19 GB-07.2005...

  • Page 30: Static Discharge

    When operating in winter, take care: Increased danger of slipping, especial when cleaning Keep steps and platforms free of snow and ice Risk of blockages due to ice in the conveying pipe THP 94/42 R 4 XXT THP 125/42 R 4 XXT 2-20 GB-07.2005...

  • Page 31: Storms And Thunderstorms

    First aid Information should be sought for treatment of injuries that may arise when working with the truck-mounted concrete pump. Injuries must be reported to the supervisor. THP 94/42 R 4 XXT THP 125/42 R 4 XXT 2-21 GB-07.2005 THP 140 H/42 R 4 XXT...

  • Page 32: Responsible Persons

    Personnel who are being trained, taught, instructed or educated on the machine may use it only under continuous supervision of an experienced operator. If no skilled personnel or workshop equipment etc. are available, apply to WAITZINGER Customer Service for maintenance of your machine.

  • Page 33: Safety And Warning Notices

    14 WAI106370 Fully extend the outrigger 29 WAI104770 supports 15 WAI106366 max. inclination 3º Fig. 2.16 Overview of safety and warning notices THP 94/42 R 4 XXT THP 125/42 R 4 XXT 2-23 GB-07.2005 THP 140 H/42 R 4 XXT...
  • Page 34 AFETY INSTRUCTIONS AND INFORMATION HAPTER Fig. 2.17 Item 1 - WAI106179 - Serial plate Fig. 2.18 Item 2 - WAI106032 - Matching pipe lenghts / Conveying pipes THP 94/42 R 4 XXT THP 125/42 R 4 XXT 2-24 GB-07.2005 THP 140 H/42 R 4 XXT...
  • Page 35 AFETY INSTRUCTIONS AND INFORMATION HAPTER Fig. 2.19 Item 3 - WAI105933/WAI105932 - General instructions (GB/D) THP 94/42 R 4 XXT THP 125/42 R 4 XXT 2-25 GB-07.2005 THP 140 H/42 R 4 XXT...
  • Page 36 AFETY INSTRUCTIONS AND INFORMATION HAPTER Fig. 2.20 Item 4 - WAI105944 - Safety equipment Fig. 2.21 Item 5 - WAI105934 - High-tension overhead electric cables THP 94/42 R 4 XXT THP 125/42 R 4 XXT 2-26 GB-07.2005 THP 140 H/42 R 4 XXT...
  • Page 37 AFETY INSTRUCTIONS AND INFORMATION HAPTER Fig. 2.22 Item 6 - WAI105974 - Keep away Abb. 2.23 Item 7 - WAI105938 - Remotely controlled machine THP 94/42 R 4 XXT THP 125/42 R 4 XXT 2-27 GB-07.2005 THP 140 H/42 R 4 XXT...
  • Page 38 AFETY INSTRUCTIONS AND INFORMATION HAPTER Fig. 2.24 Item 8 - WAI105937 - Boom is not a crane Fig. 2.25 Item 9 - WAI105975 - Total weight of discharge hose THP 94/42 R 4 XXT THP 125/42 R 4 XXT 2-28 GB-07.2005...
  • Page 39 AFETY INSTRUCTIONS AND INFORMATION HAPTER Fig. 2.26 Item 10 - WAI105940 - Slewing range of boom Fig. 2.27 Item 11 - WAI105941 - Extending the support feet THP 94/42 R 4 XXT THP 125/42 R 4 XXT 2-29 GB-07.2005 THP 140 H/42 R 4 XXT...
  • Page 40 Fig. 2.28 Item 12 - WAI105939 - Do not reach into the hopper Fig. 2.30 Item 14 - WAI106370 - Fully extend the outrigger Fig. 2.29 Item 13 - WAI106369 - Grease point THP 94/42 R 4 XXT THP 125/42 R 4 XXT 2-30 GB-07.2005...
  • Page 41 HAPTER MAX 3° Fig. 2.31 Item 15 - WAI106366 - Max. inclination 3° Fig. 2.32 Item 16 - WAI106367 - Crush hazard THP 94/42 R 4 XXT THP 125/42 R 4 XXT 2-31 GB-07.2005 THP 140 H/42 R 4 XXT...
  • Page 42 180° 100° 9,250 9,250 9,250 10,200 0° 370° 29 m 38 m Fig. 2.33 Item 17 - WAI105976 - Distributor boom range THP 94/42 R 4 XXT THP 125/42 R 4 XXT 2-32 GB-07.2005 THP 140 H/42 R 4 XXT...
  • Page 43 Fig. 2.35 Item 19 - WAI106769 - Distributor boom serial plate Fig. 2.34 Item 18 - WAI105942 - Spring plug Fig. 2.36 Item 20 - WAI105935 - Coupling pipe wall thickness THP 94/42 R 4 XXT THP 125/42 R 4 XXT 2-33 GB-07.2005...
  • Page 44 AFETY INSTRUCTIONS AND INFORMATION HAPTER Fig. 2.37 Item 21 - WAI105936 - Keep hands out of water box Fig. 2.38 Item 22 - WAI105943 - Disengage the clutch THP 94/42 R 4 XXT THP 125/42 R 4 XXT 2-34 GB-07.2005...
  • Page 45 AFETY INSTRUCTIONS AND INFORMATION HAPTER Fig. 2.39 Item 23 - WAI106477/WAI106478 - Safety instructions (GB/D) THP 94/42 R 4 XXT THP 125/42 R 4 XXT 2-35 GB-07.2005 THP 140 H/42 R 4 XXT...
  • Page 46 Fig. 2.40 Item 24 - WAI106348 - Operating panel right hand outrigger Fig. 2.41 Item 25 - WAI106349 - Operating panel left hand outrigger Fig. 2.42 Item 26 - WAI106519 - Operating panel distributor boom THP 94/42 R 4 XXT THP 125/42 R 4 XXT 2-36 GB-07.2005...
  • Page 47 Fig. 2.43 Item 27 - WAI106030 - Operating panel agitator Fig. 2.44 Item 28 - WAI106031 - Operating panel water pump Fig. 2.45 Item 29 - WAI104770 - Operating panel supports THP 94/42 R 4 XXT THP 125/42 R 4 XXT 2-37 GB-07.2005...

  • Page 49: Technical Data

    Fig. 3.1 Leading dimensions of the truck-mounted concrete pump Truck Information regarding the truck can be found in the separate user manual supplied by the truck manufacturer. THP 94/42 R 4 XXT THP 125/42 R 4 XXT GB-07.2005 THP 140 H/42 R 4 XXT...

  • Page 50: Distributor Boom 42 R 4 Xxt

    Time element 2 up/down 180 ° [sec] Time element 3 up/down 180 ° [sec] Time element 4 up/down 235 ° [sec] Rotate left/right 370 ° [sec] THP 94/42 R 4 XXT THP 125/42 R 4 XXT GB-07.2005 THP 140 H/42 R 4 XXT...
  • Page 51 ECHNICAL DATA HAPTER 42 m 235° 180° 180° 100° 9,250 9,250 9,250 10,200 0° 370° 29 m 38 m Fig. 3.2 Diagram of ranges THP 94/42 R 4 XXT THP 125/42 R 4 XXT GB-07.2005 THP 140 H/42 R 4 XXT...

  • Page 52: Concrete Pump

    [bar] Max. hydraulic pressure, water pump [bar] Max. speed of cardan shaft [rpm] 1.650 1.650 1.650 WARNING: Note transmission ratio from vehicle gearbox! THP 94/42 R 4 XXT THP 125/42 R 4 XXT GB-07.2005 THP 140 H/42 R 4 XXT...

  • Page 53: Description

    Any use that is not covered by proper use is deemed to be improper use or misuse. WAITZINGER accepts no liability for damage that arises under such circumstances. The truck-mounted concrete pump as delivered is in accordance with current technology and complies with recognised safety standards for construction and use.
  • Page 54 13 Control panel 7 Lubrication system 14 Control panel water pump / agitator Fig. 4.1 Main components of the truck-mounted concrete pump - sheet 1 THP 94/42 R 4 XXT THP 125/42 R 4 XXT GB-07.2005 THP 140 H/42 R 4 XXT...
  • Page 55 6 Boom element C 13 Rear outrigger cylinder 7 Boom element D Fig. 4.2 Main components of the truck-mounted concrete pump - sheet 2 THP 94/42 R 4 XXT THP 125/42 R 4 XXT GB-07.2005 THP 140 H/42 R 4 XXT...

  • Page 56: Distributor Boom

    It supplies all lubrication points on the truck-mounted concrete pump (apart from the conveying piston). An optional central lubrication system is available for the conveying piston and/or distributor boom. THP 94/42 R 4 XXT THP 125/42 R 4 XXT GB-07.2005...

  • Page 57: Function Of The Concrete Pump

    4 Conveying piston 9 Conveying cylinder II 5 Slide housing with agitator 10 Left drive cylinder Fig. 4.3 Operation of the concrete pump THP 94/42 R 4 XXT THP 125/42 R 4 XXT GB-07.2005 THP 140 H/42 R 4 XXT...

  • Page 58: Method Of Operation Of The Concrete Pump

    S-valve and the left cylinder sucks concrete in from the slide housing. Sensor S11 stops Y4a and Y5a swings the S-valve back in direction “D”. A full cycle is now complete. THP 94/42 R 4 XXT THP 125/42 R 4 XXT GB-07.2005...

  • Page 59: Controls And Displays

    6 Control elements on the control cabinet 13 Cable remote control 7 Control panel desk Fig. 5.1 Controls and displays for the truck-mounted concrete pump THP 94/42 R 4 XXT THP 125/42 R 4 XXT GB-07.2005 THP 140 H/42 R 4 XXT...

  • Page 60: Control Panel Desk

    12 Indicator lamp "Suck" 6 Rocker switch "Horn-Reset/Lubrication" 13 Stroke rate potentiometer 7 Rocker switch "Light" 14 Key switch "Desk/Remote control" Fig. 5.2 Control panel desk THP 94/42 R 4 XXT THP 125/42 R 4 XXT GB-07.2005 THP 140 H/42 R 4 XXT...

  • Page 61: Control Panel Agitator / Water Pump

    4 Control lever ”Water pump / Additional Equipm.“ (optional) 5 Control lever ”Agitatot / Agitator reverse“ Fig. 5.3 Control panel Agitator / Water pump THP 94/42 R 4 XXT THP 125/42 R 4 XXT GB-07.2005 THP 140 H/42 R 4 XXT...

  • Page 62: Boom Control Block

    4 Control lever "Outrigger / Boom" 9 Control lever "Boom slew left / right" 5 Control lever "Deploy and retract boom element D" Fig. 5.4 Boom control panel THP 94/42 R 4 XXT THP 125/42 R 4 XXT GB-07.2005 THP 140 H/42 R 4 XXT...

  • Page 63: Outrigger Control Block, Left

    7 Control lever "Extending / retracting the front outrigger telescope" 8 Control lever "Extending / retracting the front outrigger cylinder" Fig. 5.5 Left outrigger control panel THP 94/42 R 4 XXT THP 125/42 R 4 XXT GB-07.2005 THP 140 H/42 R 4 XXT...

  • Page 64: Outrigger Control Block, Right

    7 Control lever "Slewing the rear outrigger out / in" 8 Control lever "Extending / retracting the rear outrigger cylinder" Fig. 5.6 Right outrigger control panel THP 94/42 R 4 XXT THP 125/42 R 4 XXT GB-07.2005 THP 140 H/42 R 4 XXT...

  • Page 65: Control Cabinet

    1 Display instrument "Operating hours" 2 Rotary switch "Back-up function A-0-B" 3 Indicator lamp "Fault" 4 Indicator lamp "Lubrication system" Fig. 5.7 Control cabinet control panel THP 94/42 R 4 XXT THP 125/42 R 4 XXT GB-07.2005 THP 140 H/42 R 4 XXT...

  • Page 66: Changeover To Transfer Shift Gearbox (In The Cab)

    5.10 Water tank shut-off valve 1 Ball valve “Water tank filling / emptying” 2 Filling and emptying connection Fig. 5.10 Water tank drain THP 94/42 R 4 XXT THP 125/42 R 4 XXT GB-07.2005 THP 140 H/42 R 4 XXT...

  • Page 67: Water Connection, Rear

    6 Push button "Frequency changeover" 14 Push button "Horn+Reset" 7 Rocker switch "Engine speed +/–" Fig. 5.12 Radio remote control / Cable remote control THP 94/42 R 4 XXT THP 125/42 R 4 XXT GB-07.2005 THP 140 H/42 R 4 XXT...

  • Page 68: Emergency Stop Button

    5 Valve Y5a 2 Push button 6 Valve Y4a 3 Valve Y3 7 Valve Y4b 4 Pressure sensor Fig. 5.14 Hydraulic block THP 94/42 R 4 XXT THP 125/42 R 4 XXT 5-10 GB-07.2005 THP 140 H/42 R 4 XXT...

  • Page 69: Driving, Towing, Loading

    Further information on towing can be found in the separate vehicle manufacturer’s user manual. THP 94/42 R 4 XXT THP 125/42 R 4 XXT GB-07.2005...

  • Page 70: Towing

    Always check before lifting! The attachment points for lifting the truck-mounted concrete pump are specifically identified. A transport company should be entrusted with loading and transporting by crane if necessary. THP 94/42 R 4 XXT THP 125/42 R 4 XXT GB-07.2005...

  • Page 71: Starting Up And Operating

    Hard hat Safety boots Ear defenders Safety gloves Safety glasses Face mask Protective clothing Safety harness Fig. 7.1 Symbols for personal safety equipment THP 94/42 R 4 XXT THP 125/42 R 4 XXT GB-07.2005 THP 140 H/42 R 4 XXT...

  • Page 72: General Information For Operating The Truck-Mounted Concrete Pump

    Clean the conveying pipes using a cleaning ball and water Clean the hopper and the complete machine Perform routine maintenance, and repair any faults that have developed whilst the machine was running THP 94/42 R 4 XXT THP 125/42 R 4 XXT GB-07.2005...

  • Page 73: Setting Up The Truck-Mounted Concrete Pump

    On sloping ground put chocks behind the wheels, release the brakes and allow the truck-mounted concrete pump to roll back on to the chocks. Then apply the handbrake and extend the outriggers. The ground must be checked for its load-bearing capability. THP 94/42 R 4 XXT THP 125/42 R 4 XXT GB-07.2005...

  • Page 74: Adjustments And Actions Before Starting Up

    Selecting the wrong gear can lead to overspeeding and damage to the WARNING hydraulic pumps! Engine braking must be disengaged! The handbrake must be applied! THP 94/42 R 4 XXT THP 125/42 R 4 XXT GB-07.2005 THP 140 H/42 R 4 XXT...

  • Page 75: Emergency Stop

    The controls must be reset after an Emergency Stop by pressing the “Horn/Reset” rocker switch (Item 6, Fig. 5.2) on the control panel desk. All functions that were in operation when the Emergency Stop button was pressed must be restarted. THP 94/42 R 4 XXT THP 125/42 R 4 XXT GB-07.2005...

  • Page 76: Selecting The Operating Mode

    Operating the outriggers DANGER: When the outriggers are being slewed in/out or extended DANGER there is high crush risk hazard. THP 94/42 R 4 XXT THP 125/42 R 4 XXT GB-07.2005 THP 140 H/42 R 4 XXT...

  • Page 77: Stability Checking

    • The outriggers are secured in the stowed position for vehicle travel by hydraulically locked catches. WARNING: Before moving the vehicle and before starting work make absolutely sure WARNING that the hydraulically locked catches are engaged! THP 94/42 R 4 XXT THP 125/42 R 4 XXT GB-07.2005 THP 140 H/42 R 4 XXT...

  • Page 78: Back-Up Operation

    7 Slewing the rear outrigger cylinder out / in 8 Extending / retracting the rear outrigger cylinder Fig. 7.8 Outrigger control block, right THP 94/42 R 4 XXT THP 125/42 R 4 XXT GB-07.2005 THP 140 H/42 R 4 XXT...

  • Page 79: Building Up The Outrigger

    • The truck-mounted concrete pump may not stand more than 3° from level. Check the circular levels Circular level Fig. 7.10 Setting up the truck-mounted concrete pump using the circular level THP 94/42 R 4 XXT THP 125/42 R 4 XXT GB-07.2005...

  • Page 80: Distributor Boom Operation

    Pressing the control lever downwards rotates the boom Fig. 7.11 Controll. the distrib. boom from the boom control block clockwise, pressing the control lever upwards rotates the boom anticlockwise. THP 94/42 R 4 XXT THP 125/42 R 4 XXT 7-10 GB-07.2005...
  • Page 81 • Press the boom rotation control lever (Item 9, Fig. 7.11) to rotate the boom package into the working position. Fig. 7.13 Slew the boom package into the working position THP 94/42 R 4 XXT THP 125/42 R 4 XXT 7-11 GB-07.2005...
  • Page 82 • Press control lever C (Item 6, Fig. 7.11) and deploy boom element C at 90º to boom element B. Fig. 7.15 Deploy boom element C THP 94/42 R 4 XXT THP 125/42 R 4 XXT 7-12 GB-07.2005 THP 140 H/42 R 4 XXT...

  • Page 83: Back-Up Slewing Function

    If the controls system fails, slewing the boom must be enabled by engaging the additional back-up controls (Item X, Fig. 7.11) by inserting a suitable screwdriver (4 mm) into the holes in the cover and pushing. THP 94/42 R 4 XXT THP 125/42 R 4 XXT 7-13 GB-07.2005...

  • Page 84: Controlling The Distributor Boom Using The Radio Remote Control Pendant

    • Open the catch and release the discharge hose (see Fig. 7.17). • Use the joystick s(1 to 3) on the radio remote control to move the distributor boom to the desired working position. THP 94/42 R 4 XXT THP 125/42 R 4 XXT 7-14 GB-07.2005...

  • Page 85: Controlling The Distributor Boom Using The Cable Remote Control Pendant

    • Open the catch and release the discharge hose (see Fig. 7.17). • Use the joystick s(1 to 3) on the radio remote control to move the distributor boom to the desired working position. THP 94/42 R 4 XXT THP 125/42 R 4 XXT 7-15 GB-07.2005...

  • Page 86: Pump Operation

    (Item 4, Fig. 7.21) on the control panel desk will light. Sucking the concrete back remains available. The hydraulic system must be cooled down as quickly as possible by appropriate means (see section 7.6.4). THP 94/42 R 4 XXT THP 125/42 R 4 XXT 7-16 GB-07.2005...

  • Page 87: Back-Up Function For "Pump/Suck

    • Set the Back-up Pump control selector switch (Item 2, Fig. 5.7) to position “A or B” If the pump does not start (see trouble-shooting), back-up operation may be necessary in two possible fault situations: THP 94/42 R 4 XXT THP 125/42 R 4 XXT 7-17 GB-07.2005...
  • Page 88 The stroke rate, the power control and switching speed do not function in setting “A”. The concrete delivery can only be changed via engine speed. A lower gear should generally be engaged on the vehicle gearbox. THP 94/42 R 4 XXT THP 125/42 R 4 XXT 7-18 GB-07.2005...

  • Page 89: Pump Control At The Hydraulic Control Block

    3 Valve Y3 5 Valve Y5a 7 Valve Y4b 2 Push button 4 Pressure sensor 6 Valve Y4a Fig. 7.23 Pump hydraulic control block THP 94/42 R 4 XXT THP 125/42 R 4 XXT 7-19 GB-07.2005 THP 140 H/42 R 4 XXT...

  • Page 90: Agitator

    / water pump (optionally: high pressure water pump and compressor). The maximum pressure that can be set is 210 bar. Fig. 7.24 Control panel Agitator / Water pump THP 94/42 R 4 XXT THP 125/42 R 4 XXT 7-20 GB-07.2005...

  • Page 91: Water Pump

    (Item 6, Fig. 7.25). If the Emergency Stop button has been pressed, provided all Emergency Stop buttons has been released, the controls will be switched on again (reset). THP 94/42 R 4 XXT THP 125/42 R 4 XXT 7-21 GB-07.2005...

  • Page 92: Light

    Distributor boom manometer The manometer (Item 1, Fig. 7.26) shows the actual pressure at the distributor boom. Fig. 7.26 Boom control block THP 94/42 R 4 XXT THP 125/42 R 4 XXT 7-22 GB-07.2005 THP 140 H/42 R 4 XXT...

  • Page 93: Filter Clogging Display

    Maximum pressure 5 bar, see manometer (Item 1, Fig. 7.28). Pull and twist the rotary controller (Item 2, Fig. 7.28) to adjust the pressure. Fig. 7.28 Manometer transfer shift gearbox THP 94/42 R 4 XXT THP 125/42 R 4 XXT 7-23 GB-07.2005...

  • Page 94: Instructions For Pump Operation

    (high conveying resistance), do not increase the conveying quantity until you have pumped several m continuously. Fig. 7.29 Conveying quantity diagram THP 94/42 R 4 XXT THP 125/42 R 4 XXT 7-24 GB-07.2005 THP 140 H/42 R 4 XXT...

  • Page 95: Causes Of Blockages

    The following causes may lead to this: • The outriggers may have moved – repeat the outrigger set-up procedure, see section 7.3.4 WARNING: Before restarting, determine the reason why the outriggers had moved. THP 94/42 R 4 XXT THP 125/42 R 4 XXT 7-25 GB-07.2005...

  • Page 96: Instructions For Pumping (Depending On The Material To Be Pumped)

    Air inclusions occur particular when pumping through by sucking in air when the hopper is insufficiently filled with concrete and when the conveying pipework has been extended. • The characteristics of the concrete must not be changed in any way. THP 94/42 R 4 XXT THP 125/42 R 4 XXT 7-26 GB-07.2005...

  • Page 97: Instructions For Pumping (Depending On The Machine)

    • Set the engine speed to more than the minimum speed (500-700 rpm). • Damage due to operator error is not covered by the WAITZINGER warranty. • If the temperature continues to rise, change the water continuously. Discover the cause of the overheating and rectify it.

  • Page 98: Measures To Reduce The Oil Temperature

    (the hollow ring Fig. 7.33 cleaning sponge in suction cleaning is recognisable). THP 94/42 R 4 XXT THP 125/42 R 4 XXT 7-28 GB-07.2005 THP 140 H/42 R 4 XXT...

  • Page 99: Cleaning With Pressurised Water

    • Push 2 or 3 cleaning sponges soaked with water into Fig. 7.34 Cleaning with water hose the cleaning port and the seal the cleaning port tightly. THP 94/42 R 4 XXT THP 125/42 R 4 XXT 7-29 GB-07.2005...
  • Page 100 If there is a risk of frost, drain the wash-out tank, water tank and water pump. The wash-out tank should also be drained at normal temperatures during long pauses in pumping, overnight and at weekends. THP 94/42 R 4 XXT THP 125/42 R 4 XXT 7-30 GB-07.2005...

  • Page 101: Draining The Remaining Concrete

    2, Fig. 7.37). • Keep filling with water until water emerges from the filler Fig. 7.38 Fill with water using the C-coupling opening. THP 94/42 R 4 XXT THP 125/42 R 4 XXT 7-31 GB-07.2005 THP 140 H/42 R 4 XXT...

  • Page 102: Filling With Water From The Mixer Truck

    • The machine must be standing level; level the machine using the circular levels (Item 1, Fig. 5.5 and Item 3, Fig. 5.6). • Completely drain all water by opening all ball valves (Item 2, Fig. 7.38 and Item 2, Fig. 7.39). • Drain the wash-out tank THP 94/42 R 4 XXT THP 125/42 R 4 XXT 7-32 GB-07.2005...
  • Page 103 Trouble-shooting should be performed based on the following table. Only skilled technical staff should investigate the causes of faults and implement measures to rectify the fault. If the fault cannot be rectified, contact WAITZINGER customer service. Tracing faults Fault...

  • Page 104: Trouble-Shooting

    7.6.4. Spool valve defective. Check valve and solenoid, and have part replaced if necessary by WAITZINGER customer service. THP 94/42 R 4 XXT THP 125/42 R 4 XXT 8 - 2 GB-07.2005 THP 140 H/42 R 4 XXT...
  • Page 105 7.6.2. Check the conveying piston for wear. Concrete mixture unsuitable Use only “pumping concrete”, for pumping. see section 7.6.3. THP 94/42 R 4 XXT THP 125/42 R 4 XXT 8 - 3 GB-07.2005 THP 140 H/42 R 4 XXT...
  • Page 106 Seek advice from WAITZINGER customer service on this point. THP 94/42 R 4 XXT THP 125/42 R 4 XXT 8 - 4 GB-07.2005 THP 140 H/42 R 4 XXT...
  • Page 107 WARNING: The boom cylinder must be bled. Seek advice from WAITZINGER customer services on this point. THP 94/42 R 4 XXT THP 125/42 R 4 XXT 8 - 5 GB-07.2005 THP 140 H/42 R 4 XXT...
  • Page 108 Set the pressures to the data sheet values. If necessary, replace the valves. Seek advice from WAITZINGER customer service on this point. THP 94/42 R 4 XXT THP 125/42 R 4 XXT 8 - 6 GB-07.2005 THP 140 H/42 R 4 XXT...
  • Page 109 Water tank empty. Fill up with water. Agitator switched on. Switch the agitator off using the control lever (Item 5, Fig. 5.3). THP 94/42 R 4 XXT THP 125/42 R 4 XXT 8 - 7 GB-07.2005 THP 140 H/42 R 4 XXT...
  • Page 110 Lubrication distributor blocked. Replace the grease up to the lubrication distributor and replace the lubrication distributor. Pump impeller defective. replace pump impeller. THP 94/42 R 4 XXT THP 125/42 R 4 XXT 8 - 8 GB-07.2005 THP 140 H/42 R 4 XXT...

  • Page 111: General Information

    Used cleaning materials must be removed from the truck-mounted concrete pump and placed in a specially designated container (fire hazard!). The use of highly flammable materials (e.g. petrol) is prohibited - VBG 1 § 43 and 44! THP 94/42 R 4 XXT THP 125/42 R 4 XXT GB-07.2005...

  • Page 112: Lubricants And Solvents

    When handling these materials wear protective clothing at all times (skin, eyes, hand and foot protection). Used protective clothing must be placed in sealed plastic sacks after wearing. THP 94/42 R 4 XXT THP 125/42 R 4 XXT GB-07.2005 THP 140 H/42 R 4 XXT...

  • Page 113: Sealing Rings (Containing Fluorine)

    To avoid severe infections, call a doctor immediately. Dispose of oils and filters in accordance with statutory regulations. Never pour lubricating oil down the public drains. THP 94/42 R 4 XXT THP 125/42 R 4 XXT GB-07.2005 THP 140 H/42 R 4 XXT...

  • Page 114: Paints, Varnishes And Thinners

    Even gases which are not themselves flammable can decompose at high temperatures and release poisonous gases, e.g. when drawn through the glowing tip of a cigarette. Thus the same safety instructions apply as for paraffin and petrol. THP 94/42 R 4 XXT THP 125/42 R 4 XXT GB-07.2005...

  • Page 115: Battery Acid

    Then immediately summon a doctor. Because of the risk of an explosion, keep sparks and naked flames away from batteries. Battery acid can catch fire. THP 94/42 R 4 XXT THP 125/42 R 4 XXT GB-07.2005 THP 140 H/42 R 4 XXT...

  • Page 116: Safety Precautions When Charging Batteries

    Attach the earth connection immediately adjacent to the welding location! In addition, observe all safety instructions set out in Chapter 2 Safety Instructions! THP 94/42 R 4 XXT THP 125/42 R 4 XXT GB-07.2005...

  • Page 117: Tightening Torques For Screw Connections

    µ = 1.25 (lightly oiled). Tightening torque M [Nm] Tightening torque M [Nm] Thread Ø 10.9 1.400 Fig. 9.1 Tightening torque for screw connections THP 94/42 R 4 XXT THP 125/42 R 4 XXT GB-07.2005 THP 140 H/42 R 4 XXT...

  • Page 118: Maintenance Schedule

    Lubricate the conveying piston with grease (unless the automatic piston lubrication option is fitted). Visually check all hydraulic lines and screwed joints for leak-tightness. THP 94/42 R 4 XXT THP 125/42 R 4 XXT GB-07.2005 THP 140 H/42 R 4 XXT...
  • Page 119 Check the adjustment of the S-valve and adjust it as necessary. After at least 24 hours settling time check the condensation water in the hydraulic oil tank; drain it through the ball valve until hydraulic oil comes out. THP 94/42 R 4 XXT THP 125/42 R 4 XXT GB-07.2005...
  • Page 120 Check engine speed and operation of the pump together with stroke rate against the data sheet, see sections 3.3 and 3.4. Check that the conveying piston fastenings are tight. THP 94/42 R 4 XXT THP 125/42 R 4 XXT 9-10 GB-07.2005...
  • Page 121 Check play within the ball bearing slewing rim, see section 9.8.6. Change the oil in the slewing gearbox, see section 9.7.1. Change the oil in the transfer shift gearbox, see section 9.7.2. THP 94/42 R 4 XXT THP 125/42 R 4 XXT 9-11 GB-07.2005...

  • Page 122: Lubrication

    After waiting no more than 4 minutes the control pin in the lubrication distributor must be seen to move in and out. 4. Checking the lubrication pipes CAUTION: Immediately replace any defective lubrication pipes! CAUTION THP 94/42 R 4 XXT THP 125/42 R 4 XXT 9-12 GB-07.2005 THP 140 H/42 R 4 XXT...

  • Page 123: Checking The Grease Nipples For Manual Lubrication

    If no grease can be injected into a lubrication point, this problem must be rectified as soon as possible by a WAITZINGER customer service fitter. Control pin 6 Oscillation cylinder 7 Swing lever Fig. 9.2 Lubrication system THP 94/42 R 4 XXT THP 125/42 R 4 XXT 9-13 GB-07.2005 THP 140 H/42 R 4 XXT...

  • Page 124: Manual Lubrication

    9.5.3 Sliding surfaces Use graphite grease for sliding surfaces, see Figure 9.5. 9.5.4 Overview of grease points Fig. 9.3 Grease points overview THP 94/42 R 4 XXT THP 125/42 R 4 XXT 9-14 GB-07.2005 THP 140 H/42 R 4 XXT...
  • Page 125 = 2 Schmiernippel auf der Innenseite, gegenüberliegend = 2+2 Schmiernippel auf der Innenseite, gegenüberliegend = Flächenschmierung Fig. 9.3 Grease points overview Boom control block THP 94/42 R 4 XXT THP 125/42 R 4 XXT 9-15 GB-07.2005 THP 140 H/42 R 4 XXT...

  • Page 126: Reference Tables For Hydraulic Oils, Greases And Gear Oils

    Reference tables for hydraulic oils, greases and gear oils Lubricants suitable for the truck-mounted concrete pump are listed in table below. WAITZINGER Takes no responsibility for the quality of the lubricants that are listed, nor for variations in their quality.
  • Page 127 -15 °C Dolon E 2 FUCHS Plantogel S2 Li/Ca – -20 °C KLÜBER Klüberbio M32 - 82 Fig. 9.5 Greases reference table THP 94/42 R 4 XXT THP 125/42 R 4 XXT 9-17 GB-07.2005 THP 140 H/42 R 4 XXT...
  • Page 128 Synthetic Roller bearing Öl – CLP DIN 51517 Öl – PGLP DIN 51502 Low-viscosity grease Grease Fig. 9.6 Gearbox oils reference table THP 94/42 R 4 XXT THP 125/42 R 4 XXT 9-18 GB-07.2005 THP 140 H/42 R 4 XXT...

  • Page 129: Changing Filters

    NOTE: Do not let hydraulic oil drain into the ground, always use a sufficiently large bowl or container and dispose of it in accordance with the applicable regulations. THP 94/42 R 4 XXT THP 125/42 R 4 XXT 9-19 GB-07.2005...

  • Page 130: High-Pressure Filters For The Boom And Hydraulic Pumps

    7. Check filter for leak-tightness. NOTE: When changing the return-flow filter, always Fig. 9.8 Changing the return flow filter change the air filter (6) also! THP 94/42 R 4 XXT THP 125/42 R 4 XXT 9-20 GB-07.2005 THP 140 H/42 R 4 XXT...

  • Page 131: In-Line Filter Cartridge

    A. Fig. 9.10 Slewing gearbox 5. Screw in the air bleed screw and the breather screw. THP 94/42 R 4 XXT THP 125/42 R 4 XXT 9-21 GB-07.2005...

  • Page 132: Changing The Oil In The Transfer Shift Gearbox

    1. Remove the drain plug from the drain cock (Item 1, Fig. 9.12). Fig. 9.12 Oil drain pipe 2. Connect a ∫” hose from the drain cock to the container. THP 94/42 R 4 XXT THP 125/42 R 4 XXT 9-22 GB-07.2005...
  • Page 133 NOTE: Before operating the hydrau- lics, first run the system at idling for 15 minutes. Fig. 9.14 Hydraulic oil tank sight glass THP 94/42 R 4 XXT THP 125/42 R 4 XXT 9-23 GB-07.2005 THP 140 H/42 R 4 XXT...

  • Page 134: Performing Tests

    Replace worn parts. • The wall thickness can also be measured using a special wall thickness gauge. Fig. 9.15 Measuring the wall thickness of the conveying pipework THP 94/42 R 4 XXT THP 125/42 R 4 XXT 9-24 GB-07.2005 THP 140 H/42 R 4 XXT...

  • Page 135: Minimum Wall Thicknesses And Conveying Pipework Operating Pressures

    DN = Nominal diameter Conveying pipework designation: Standard size Maximum pressure Code Minimum wall thickness [mm] Fig. 9.16 Minimum wall thickness diagram THP 94/42 R 4 XXT THP 125/42 R 4 XXT 9-25 GB-07.2005 THP 140 H/42 R 4 XXT...

  • Page 136: Adjusting The S-Valve

    • Use the adjustment nut (1) to tighten the chain until the correct sag of 30 mm is achieved. 30 mm Fig. 9.18 Checking the chain tension THP 94/42 R 4 XXT THP 125/42 R 4 XXT 9-26 GB-07.2005 THP 140 H/42 R 4 XXT...

  • Page 137: Checking The Backlash In The Slewing Gearbox

    • The measurement must be performed at 2 points (loa- ded side and unloaded side) as shown in the diagram alongside. Fig. 9.21 Measurement points for checking the boom backlash THP 94/42 R 4 XXT THP 125/42 R 4 XXT 9-27 GB-07.2005...

  • Page 138: Checking The Operation Of The Sensors

    (3) to the end of its travel to check the Fig. 9.23 Checking the operation of the sensors operation of the sensor (4). THP 94/42 R 4 XXT THP 125/42 R 4 XXT 9-28 GB-07.2005 THP 140 H/42 R 4 XXT...

  • Page 139: Replacing Worn Parts

    9.3. 9. Perform a trial run. Fig. 9.25 Changing the wear plate and wear ring 2 THP 94/42 R 4 XXT THP 125/42 R 4 XXT 9-29 GB-07.2005 THP 140 H/42 R 4 XXT...

  • Page 140: Changing The Conveying Piston

    4. Push the conveying piston (1) about 5 mm towards the conveying cylinder by levering with a pry bar, and remove the spacer (3). Fig. 9.27 Changing the conveying piston 2 THP 94/42 R 4 XXT THP 125/42 R 4 XXT 9-30 GB-07.2005...
  • Page 141 Fig. 9.29 Changing the conveying piston 4 7. Liberally lubricate the new conveying piston (1), attach a shell coupling (4) and fit it. Fig. 9.30 Changing the conveying piston 5 THP 94/42 R 4 XXT THP 125/42 R 4 XXT 9-31 GB-07.2005...

  • Page 142: Changing / Turning The Conveying Cylinder

    Fig. 9.32 Changing / turning the conveying cylinder NOTE: When lifting, take care that no hoses or cables are trapped! 6. Remove or turn the conveying cylinder. THP 94/42 R 4 XXT THP 125/42 R 4 XXT 9-32 GB-07.2005 THP 140 H/42 R 4 XXT...

  • Page 143: Changing The Agitator Blades

    3. Fit the screws (2) and tighten them to the torque set out in the table in section 9.3. Always replace these screws. Fig. 9.33 Changing the agitator blades THP 94/42 R 4 XXT THP 125/42 R 4 XXT 9-33 GB-07.2005...

  • Page 144: Changing The Agitator Seals

    6. Refit the agitators in the reverse sequence to removal. A new hole must be drilled for the securing pin (8). Fig. 9.35 Changing the agitator wear sleeves THP 94/42 R 4 XXT THP 125/42 R 4 XXT 9-34 GB-07.2005...

  • Page 145: Changing The Conveying Pipework

    CAUTION outriggers must be rectified immediately they are noticed! To do this, request the WAITZINGER repair guide without delay! Repairs must only be performed by an authorised specialist company! • For crack checking the machine must be clean. Excess grease on the joints must be removed.

  • Page 146: Checking The Hoses

    If a hose splits suddenly under pressure, personnel can be seriously DANGER injured! WAITZINGER takes no responsibility for damages that result from the use of worn or defective components. Regular checking of hoses is part of the technical safety checks to be performed on the machine.

  • Page 147: Disposal Of The Machine

    9.14 Disposal of the machine NOTE: Observe national and regional legislative regulations and guidelines when disposing of the machine. THP 94/42 R 4 XXT THP 125/42 R 4 XXT 9-37 GB-07.2005 THP 140 H/42 R 4 XXT...

  • Page 149: Repair Work

    Repair work must only be performed by trained personnel or service WARNING personnel who have been authorised by WAITZINGER! The user is not permitted to carry out repair work on his own account. Any work on the machine in breach of this provision will render the...

  • Page 151: List Of Operators Of The Equipment

    • He agrees to comply with all instructions conscientiously. • If he does not do so, the manufacturer’s warranty will become void. Operator name Accepted on Operator signature THP 94/42 R 4 XXT THP 125/42 R 4 XXT 11-1 GB-07.2005 THP 140 H/42 R 4 XXT...
  • Page 152 IST OF OPERATORS OF THE EQUIPMENT HAPTER Make further copies if required Operator name Accepted on Operator signature THP 94/42 R 4 XXT THP 125/42 R 4 XXT 11-2 GB-07.2005 THP 140 H/42 R 4 XXT...

  • Page 153: Maintenance And Modifications List

    • This maintenance and modifications list should be made available on request to the “Employers’ Liability Insurance Association” or the “TÜV” properly filled in and signed. Maintenance Modification Date Operator Confirmed by signature person responsible THP 94/42 R 4 XXT THP 125/42 R 4 XXT 12-1 GB-07.2005 THP 140 H/42 R 4 XXT...
  • Page 154 AINTENANCE AND MODIFICATIONS LIST HAPTER Make further copies if required Maintenance Modification Date Operator Confirmed by signature person responsible THP 94/42 R 4 XXT THP 125/42 R 4 XXT 12-2 GB-07.2005 THP 140 H/42 R 4 XXT...
  • Page 155 AINTENANCE AND MODIFICATIONS LIST HAPTER Make further copies if required Maintenance Modification Date Operator Confirmed by signature person responsible THP 94/42 R 4 XXT THP 125/42 R 4 XXT 12-3 GB-07.2005 THP 140 H/42 R 4 XXT...

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