Putzmeister BSA 1005 D3B C Operating Instructions Manual

Stationary concrete pump

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Operating Instructions

for machine operator and maintenance staff

always keep by the machine

Translation of the original Operating Instructions

Stationary

concrete pump

Machine no.

16−04−07

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

BSA 1005 D3B C

210109379

E Putzmeister Concrete Pumps GmbH 1994

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Page 1 Translation of the original Operating Instructions Stationary concrete pump BSA 1005 D3B C Machine no. 210109379 16−04−07 The paper on which this document is printed is 100% chlorine free E Putzmeister Concrete Pumps GmbH 1994...
Page 2 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. +90−282−735−1000 pm@putzmeister.com.tr G.O.Pa a Mah. Nam k Kemal Bulvar No: 6 +90−282−738−1001 www.putzmeister.com.tr 59500 Çerkezköy / TEK RDA Putzmeister America +1−262−886−3200...
Page 3 Übersetzung der Originalbetriebsanleitung Ïðåâîä íà îðèãèíàëíî Ðúêîâîäñòâî çà ðàáîòà P eklad originálního návodu k obsluze Oversættelse af den originale driftsvejledning MetÜfrash tou prwtotýpou twn odhgiþn leitourgßaj Translation of the original Operating Instructions Traducción de las instrucciones de servicio originales Algupärase kasutusjuhendi tõlge Alkuperäisen käyttöohjeen käännös Traduction des instructions de service originales Prijevod izvornika naputka za uporabu...
Page 5 Table of contents Table of contents Guide to the Operating Instructions Foreword ......... . . 1 —...
Page 6 Table of contents 2.3.4 Extending the reach ........2.3.5 Extending the placing boom and end hose .
Page 7 Table of contents 2.11.2 Supporting ground ........2.11.3 Corner bearing loads .
Page 8: Table Of Contents
Table of contents 2.16 Requirements for special work ..... . . 2 — 50 2.17 Welding ..........2 —...
Page 9 Table of contents General technical description Overview ......... . . 3 —...
Page 10 Table of contents Hydraulic control devices ......3 — 74 3.7.1 Output controller .
Page 11 Table of contents Transport, setting up and connection Transport ......... . . 5 —...
Page 12 Table of contents Pumping operations Preconditions ........6 —...
Page 13 Table of contents Maintenance Daily tasks ......... . 7 —...
Page 14 Table of contents Maintenance cards 00−001 Visual checks ....... 03−002 Function checks .
Page 15 Table of contents Index of key words Glossary G–1 Symbols for concrete pumps in accordance with German Mechanical Engineering Association Standard (VDMA 24119) ........G —...
Page 17 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 Condrete Pumps GmbH After Sales Department Max−Eyth−Straße 10 D−72631 Aichtal Germany Telephone +49 7127 599−0...
Page 19 Guide to the Operating Instructions 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.
Page 20 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 AP01_002_0802EN...
Page 21 Guide to the Operating Instructions 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...
Page 22 Guide to the Operating Instructions 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.
Page 23 Guide to the Operating Instructions 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...
Page 25 Safety regulations This chapter corresponds to the contents of the VDMA brochure entitled Safety manual Concrete delivery and placing machines". Here you will find a summary of the most important safety regula tions. This chapter is, therefore, particularly suitable as an initial basic instruction for new operators.
Page 27 Safety regulations Definition of terms The terms used in this Safety Manual are explained below, along with descriptions of the requirements placed on specific groups of people. 2.1.1 Machine In this Safety Manual, concrete delivery and placing machines refer − Truck−mounted concrete pumps (ensemble of truck, concrete pump with and without placing boom).
Page 28 Safety regulations 2.1.7 Truck mixer In this Safety Manual, truck mixers are vehicles with mixing equip ment for transporting concrete. 2.1.8 Delivery line systems For the purposes of this Safety Manual, delivery line systems are de fined as self−contained pipes or hoses in which concrete is pumped from the concrete pump to the placement site.
Page 29 Safety regulations 2.1.15 Truck mixer driver Person who supplies the concrete pump with concrete from a truck mixer. Truck mixer drivers must be instructed by the machine oper ator to operate the operating elements on the concrete pump pro vided for their use. Truck mixer drivers must be able to indepen dently evaluate all dangerous situations which may occur when working in the area of the hopper of a concrete pump, and to react according to the situation.
Page 30 Safety regulations 2.1.21 Place of work, working area, danger zone Mobile machines ab0005 Example Stationary machines ab0010 Example BP03_076_1601EN...
Page 31 Safety regulations Pos. Designation Explanation Machine operator In normal operation, with the remote control Place of work Hoseman At the end hose in the danger zone (during pump (during pump Signaller In the machine operator’s range of vision ing oper ing oper Auxiliary personnel As manual placing system operators...
Page 32 Safety regulations Place of work The place of work is the area in which people must remain in order to carry out the work. Place of work − ma The machine operator’s place of work is with the remote control when chine operator the pump is in operation.
Page 33 Safety regulations 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.
Page 34 Safety regulations 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.
Page 35 Safety regulations Designated use The machine must only be operated as intended and in technically perfect condition. All protective and safety oriented devices, particu larly removable protective devices and EMERGENCY STOP devices, must be available and fully functional. The machine is designed exclusively for the delivery and placing of concrete up to a bulk density of 2400 kg/m .
Page 36 Safety regulations 2.2.2 Inspection intervals The inspection intervals are fixed as follows: for retesting Machines of up to and including 5 years old: Inspect after every 1,000 operating hours or 1 year, whichever is soonest. The interval is repeated after every retest. Machines more than 5 years old: Inspect after every 500 operating hours or 1 year, whichever is soonest.
Page 37 Safety regulations Use contrary to desig- Any use of the machine which is not described in section 2.2, en nated use titled Designated use", or which extends beyond the uses de scribed in this section is deemed to be contrary to designated use. The manufacturer accepts no liability for damage resulting from such use.
Page 38 Safety regulations 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.
Page 39 Safety regulations 2.3.7 Impermissible work- The end hose must not be moved backwards beyond the vertical of ing area the placing boom. wz0026 2.3.8 Climbing the placing It is prohibited to climb the placing boom, to stand on top of it or to boom misuse it as a working platform or aid to climbing.
Page 40 Safety regulations 2.3.9 High–pressure deliv- It is prohibited to deliver concrete at high−pressure (concrete pres sure greater than 85 bar) through the delivery line of the placing boom. Delivery line elements are marked with the maximum permiss ible delivery pressure. The delivery line and end hose are only suit able for concrete pressures of up to 85 bar until the wear threshold is reached.
Page 41 Safety regulations 2.5.1 Requirements Persons operating or carrying out maintenance work on the machine must meet the following requirements: − They must be aged 18 years or over. − They must be physically and mentally capable. − They must be physiologically capable (rested and not under the influence of alcohol, drugs or medication).
Page 42 Safety regulations 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 before working with the machine, particularly the section Safety Regulations and the Safety Manual. Reading the instructions after work has begun is too late.
Page 43 Safety regulations 2.6.2 Operating procedures The operator must produce operating procedures for his personnel in accordance with national regulations. These operating procedures must include instructions covering the duties involved in supervising and notifying special organisational features, e.g. organization of work, working procedures or the personnel entrusted with the work. Furthermore, reference must be made to other generally valid legal and otherwise mandatory regulations relating to accident prevention and environmental protection.
Page 44 Safety regulations Personal protective In order to reduce risks to personnel, personal protective equipment equipment must be used in so far as this is necessary or deemed to be so by regulations. All personnel working on or with the machine must wear safety helmets, protective gloves and safety footwear.
Page 45 Safety regulations Protective gloves Protective gloves protect your hands against aggressive or chemi cal substances, as well as against mechanical effects (e.g. impact) and cutting injuries. (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.
Page 46 Safety regulations Before starting work 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. You operation must immediately report any changes (including changes in the working characteristics) to the organization or person responsible.
Page 47 Safety regulations 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.
Page 48 Safety regulations 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.
Page 49 Safety regulations 2.9.4 High–voltage warning According to the current rules of engineering, high−voltage warning devices devices do not meet a safety standard which enables a safe under shooting of the required minimum clearances to high−voltage lines. Previous experience has shown that high−voltage warning devices cannot make all situations in working procedures safe.
Page 50 Safety regulations Power stations are always equipped with automatic switch−on de vices. If a circuit breaker trips, the short−circuited cable will be switched back on again after a brief interval. Brief intervals when the voltage is absent give rise to a false sense of safety. You should only move and rescue injured persons once a represen tative of the power station has notified you that the cable has been switched off.
Page 51 Safety regulations 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. The site management must deliver the necess ary documents in good time in order to be able to prepare the foundations, base plates or similar on time.
Page 52 Safety regulations 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.
Page 53 Safety regulations 2.11 Mobile machines 2.11.1 Set–up site It is the machine operator who takes responsibility for setting up the machine safely. He must inspect the proposed set up site and must refuse to set the machine up at the site of operations if he has any doubts regarding safety.
Page 54 Safety regulations 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 pressure. If the load−bearing capacity is unknown, assume the that worst case scenario applies. wz0087 The supporting ground must be level and even.
Page 55 Safety regulations 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 clearance must be determined in accordance with the nature of the ground.
Page 56 Safety regulations 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.
Page 57 Safety regulations 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.
Page 58 Safety regulations 2.11.5 Driving When preparing the machine for driving, you must perform the fol lowing tasks in particular: − The placing boom must be folded in fully and positioned on the placing boom support provided. − The support legs and support feet must be fully retracted and se cured.
Page 59 Safety regulations 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.
Page 60 Safety regulations 2.11.7 Loading The lifting points fitted to the machine as standard are provided for assembly purposes only. They are not suitable for lifting the com plete machine. The lifting points for lifting the entire machine are specially marked. wz0176 Use only appropriate means of transport and lifting equipment of ad equate loadbearing capacity.
Page 61 Safety regulations 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.
Page 62 Safety regulations 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.
Page 63 Safety regulations 2.12.2 Guiding the 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.
Page 64 Safety regulations Never bend the end hose over. Never attempt to straighten a bent end hose by increasing the pressure. The end hose must not be sub merged below the surface of the concrete being delivered, otherwise the concrete may spray upwards. The concrete may also spray from the end hose due to the presence of air in the delivery line.
Page 65 Safety regulations 2.12.5 Procedure in storms Return the placing boom to the driving position in the event of storms or bad weather. − Placing booms with a vertical reach of 42 m or more must only be operated in winds of up to wind force 7 (wind speed 51 km/h). −...
Page 66 Safety regulations 2.13 Delivery line systems 2.13.1 Suitable delivery lines Use only delivery lines, end hoses, couplings, etc. which are in per fect condition and suitable for the delivery job, and have been ap proved by the machine manufacturer. Delivery lines are subject to wear which varies according to the pressure and composition of the concrete, the material from which the delivery line is made, etc.
Page 67 Safety regulations 2.13.3 Tightness and block- Regularly force water through the delivery line under operating pres ages sure to check that the system is watertight. wz0047 A properly−cleaned delivery line is the best insurance against the formation of blockages. Blockages increase the risk of accidents. Never attempt to push through a blockage (e.g.
Page 68 Safety regulations 2.13.4 Opening delivery lines You must not open or tap delivery lines while these are pressurized. Concrete exiting under pressure can cause injury. The concrete col umn must be depressurized by reverse pumping before the delivery line is opened. Never work bending directly over the coupling. wz0076 2.13.5 Clearance to delivery No−one should remain in the vicinity of separate delivery lines during...
Page 69 Safety regulations 2.13.7 Continuation delivery If a continuation delivery line is connected to the placing boom, it lines must not place any further strain on the placing boom. While you connect, use and disconnect a continuation delivery line, you must switch off the arm assembly control system to prevent unin tended movements of the arm assembly.
Page 70 Safety regulations 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 re mote control, all operating and control devices on the machine must be closed to prevent unauthorized interventions.
Page 71 Safety regulations 2.14.4 Moving machine com- Keep all access covers, maintenance flaps, guards, etc. closed and ponents and hot sur- locked during operation. This also applies in particular to the grille, faces water box cover and covers over cylinders. There is otherwise a risk of injury from moving parts of the machine and a risk of burning on hot surfaces.
Page 72 Safety regulations 2.15 Cleaning 2.15.1 General You must drain the delivery line, pump and hopper completely. Con crete leavings in the hopper, in particular, may be thrown out whilst the truck is moving. The machine must not be driven with the placing boom unfolded or the support legs extended, even over short distances.
Page 73 Safety regulations 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.
Page 74 Safety regulations 2.15.3 Cleaning with com- When the delivery line is being cleaned with compressed air, there is pressed air an increased risk of accidents caused by compressed air escaping explosively, spurting concrete, and delivery or end hoses moving uncontrollably if they have not been removed. Compressed air should only be used for cleaning purposes under the supervision of a subject expert.
Page 75 Safety regulations − The wash−out adaptor must be fitted with a separate, large dump cock and a pressure gauge. − The pressure gauge must be kept under constant observation dur ing the cleaning process. The pressure in the delivery line must be rapidly dumped via the dump cock in the event of a sudden drop in pressure (concrete column exiting from the end of the line) or increase in pressure (risk of blockage).
Page 76: Requirements For Special Work
Safety regulations 2.16 Requirements for In the capacity of operator, it is your responsibility to provide all the special work necessary information to the personnel concerned before special work or maintenance work is carried out. Someone should be nomi nated as the person responsible for this. Carry out the maintenance and inspection operations and comply with intervals specified in the Operating Instructions, including spec ifications for the replacement of parts and equipment.
Page 77 Safety regulations Carefully secure individual parts and large assemblies to lifting gear when carrying out a replacement operation. Use only suitable and technically perfect lifting gear and suspension systems with ad equate lifting capacity. Never stand under suspended loads. The fastening of loads and instruction of crane operators should be entrusted to experienced persons only.
Page 78: Welding
Safety regulations 2.17 Welding Only qualified personnel commissioned by the manufacturer may carry out welding work on the placing boom, on the supports or on other components which are important for safe operation. The work must be inspected by an authorized inspector. Always attach the earth cable of the welding unit directly to the com ponent which is being welded.
Page 79: Working On The Placing Boom
Safety regulations 2.18 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.
Page 80: Software
Safety regulations 2.20 Software If a machine is equipped with software, the software may only be used as is provided for in the manufacturer’s Operating Instructions. Only persons authorized by the manufacturer may intervene in the machine’s software. This also applies to updates. Unauthorized interventions in the machine’s software may lead to se vere damage and accidents.
Page 81: Electrical Power
Safety regulations 2.22 Electrical power 2.22.1 General Work on electrical systems or operating equipment must only be car ried out by qualified personnel. For further information on machines operated on the site power supply, see also section 2.22.3, entitled power at the construction site Machine components which are to undergo maintenance work must be de energized.
Page 82: 2.22.2 Electrical Components
Safety regulations 2.22.2 Electrical components Control cabinet, motor and control elements are protected as stan dard at least to degree of protection IP 54. IP 54 means: − Complete protection against contact with live components or inter nal moving parts. Protection against damaging dust deposits. −...
Page 83: Hydraulic Systems
Safety regulations 2.23 Hydraulic systems 2.23.1 General Work on hydraulic systems must only be carried out by qualified per sonnel. Always wear your personal protective equipment when carrying out work on the hydraulic system. Escaping fluid is toxic and can pen etrate the skin.
Page 84: Replacing Hydraulic Hoses
Safety regulations You must carefully bleed the hydraulic system after any maintenance work, otherwise there is a risk of injury caused by swinging and tele scopic support legs extending rapidly, the placing boom lowering, etc. Open vent valves very carefully until hydraulic fluid starts to es cape.
Page 85: Exhaust Fumes
Safety regulations 2.25 Exhaust fumes Vehicle exhaust gases contain constituents which can be lethal or carcinogenic. Operate internal combustion engines and fuel−oper ated heating systems only in adequately ventilated premises. Before starting up the engine in enclosed spaces, make sure that there is adequate ventilation and direct the exhaust gases away from the place of work.
Page 86: Disposal Of The Machine
Safety regulations 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.
Page 87 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...
Page 89: General Technical Description
General technical description Overview Below you will find an overview of the most important components; these will then be described on the following pages. Left-hand side AP21_050_1603EN 1 Pos. Component Page Documentation accompanying the machine − Engine − Hydraulic pumps −...
Page 90 General technical description Right-hand side AP21_050_1603EN 2 Pos. Component Page Output controller OPS/SPC control cabinet Magnetic switch distributor casing Cable remote control Machine rating plate Battery − Fuse box Control block − Drive cylinder emergency control lever Transfer tube emergency control lever Agitator safety cutout (RSA) AP21_050_1603EN...
Page 91: Safety Equipment
General technical description Safety equipment This illustration shows examples of safety equipment which may be fitted on the machine. AP02_330_0904EN 1 Safety equipment EMERGENCY STOP button / STOP button on the remote control Covers over the switch cylinders Side protection doors Exhaust guard Safety grille on the V−belt Transport protection...
Page 92 General technical description AP02_330_0904EN 2 Continued Safety equipment Sound proofing equipment/sound proofing kit Spray guard Grille on the hopper Danger Never operate the machine if the safety equipment is not working. You could injure yourself or others or damage the machine. Check the safety equipment as described in the Operating Instructions.
Page 93: Technical Data
General technical description 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 1005 D3B C Height 1975...
Page 94: Electromagnetic Compatibility (Emc)
Ger many by the law concerning the electromagnetic compatibility of equipment, dated 26th February 2008 (EMVG, section 4). Customer: Putzmeister AG Max−Eyth−Strasse 10 72631 Aichtal, Germany To be inspected: Concrete pump control system with ZMS−EPS...
Page 95: Machine Rating Plate
General technical description 3.3.2 Machine rating plate The following rating plate is attached to the machine: Betonpumpe BSA 1005 D3B C 210109379 BP22_830_1005EN 1 Designation Designation of the machine Machine model Machine number Maximum fluid pressure in the hydraulic system [bar]...
Page 96: Sound Pressure Level
General technical description 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 16 m. Ear de fenders must be worn in the vicinity of the machine since the sound pressure level can be higher.
Page 97 General technical description 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 1 January 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.
Page 98: Description Of The Functions
General technical description 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...
Page 99: Static Base Structure
General technical description F 80 chassis The machine may travel on public highways in the same way as a standard trailer if fitted with an F 80 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.
Page 100: Pump
S transfer tube Pressure connection 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.
Page 101 General technical description S transfer tube The S transfer 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.
Page 102: Agitator
General technical description 3.4.5 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 Designation Hydraulic motor Agitator shaft Agitator helix Improving the The filling rate in the delivery cylinders should be as high as possible...
Page 103: General Conditions For Using A Concrete Pump
General technical description 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.
Page 104: Site Of Use
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).
Page 105: Operating Temperature
General technical description 3.5.4 Operating Putzmeister must be contacted if the concrete pump is to be used temperature outside the given temperature ranges. Machine model min [° C] [° C] Truck−mounted concrete pump, Delivery line valve − 15 + 50...
Page 106: Centralized Lubrication System
General technical description 3.5.5 Centralized lubrica- The centralized lubrication system comprises a lubricant pump / tion system grease gun, lubricant distributors, relief valves and supply lines. AP02_908_1304EN 1 Designation Lubricant reservoir Lubricant pump Grease gun Lubricant distributor Agitator shaft bearings Transfer tube bearing Upper switch cylinder bearings Lower switch cylinder bearings...
Page 107 General technical description The centralized lubrication system supplies grease to the lubrication points connected to it. 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.
Page 108: Electrical Control Devices
General technical description 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.
Page 109: Control Cabinet With Spc Display Unit
General technical description 3.6.1 Control cabinet with You can control the functions of the machine from the control cabi SPC display unit net. SPC = Small Pump Control The SPC display enables you to determine the operating state of the machine.
Page 110 General technical description Continued Operating/ Pos. Meaning/function Comments control element Toggle switch Deactivate EMERGENCY STOP − 0 − Ac knowledge agitator/agitator safety cutout (RSA) Ignition−starter switch Diesel engine On − Off Toggle switch Open shut off valve − agitator − close shut off valve Toggle switch Agitator on...
Page 111 General technical description Right–hand view AP21_022_1510EN 2 Operating/ Pos. Meaning/function Comments control element Round socket, 4 pin Connection for vibrator optional Socket Connection for remote control/ Local control − Remote control Local control = replacement plug is plugged in AP21_022_1510EN...
Page 112 General technical description SPC display unit and operating elements AP21_022_1510EN 3 Operating/ Pos. Meaning/function control element Menu−driven operating states and adjustable functions SPC display are displayed in the SPC display. Momentary contact switch Function button for navigation and operation. System LED The LED of the display unit lights up when the control cabinet is supplied with power and flashes when the program is running.
Page 113 General technical description Special features of the control cabinet 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, −...
Page 114 General technical description Forward pumping − 0 − The function of the Forward pumping Reverse pumping" Reverse pumping toggle switch depends on the local or remote control. − The replacement plug is plugged in for local control. The pump can be switched over using the Forward pumping 0 Reverse pumping"...
Page 115 General technical description 3.6.2 SPC display unit The SPC display unit on the control cabinet has a graphical display and operating elements. The SPC display enables you to determine the operating state of the machine. Use the operating elements of the SPC display unit to navigate within the menu structure and apply settings.
Page 116 General technical description Appearance of the The symbols used in the SPC display appear differently depending symbols on the meaning. Colour / Appearance Meaning Background colours: Black Standard appearance Symbol colours: White Function is selected (switch or button pressed) Green Function is active Yellow Warning on the engine’s control dis...
Page 117 General technical description Menu structure The following pages show the password free section of the menu structure (example). A start screen is always displayed when the machine is started up. AP21_045_1602EN 1 AP21_045_1602EN...
Page 118 General technical description Pos. Display Function/meaning See page The start screen is displayed once the Start screen SPC display unit on the control cabinet is supplied with power. The HOME menu is the main menu. Data and HOME main instruments are displayed here. Select this menu to display data and all Expanded HOME instruments.
Page 119 General technical description Start screen The start screen in the SPC display unit is displayed for a few sec onds once the ignition−starter switch on the control cabinet is switched on. The SPC display goes out once the power supply or the engine of the stationary concrete pump is switched off.
Page 120 General technical description HOME menu The HOME menu is the main menu. Data and main instruments are displayed here. Function buttons in the HOME menu AP21_046_1602EN 1 Pos. Display Function/meaning Button The last selected start menu is opened by pressing button (1). The expanded HOME menu is opened by pressing button (2) Button in the HOME menu.
Page 121 General technical description All symbols in the menu bar AP21_046_1602EN 2 Pos. Symbol Function/meaning Back to the start menu This symbol is displayed regardless of the current menu. The symbol has no function in the HOME menu. Menu: Expanded HOME Submenu: Software information Submenu: Operating data Submenu: Engine fault code...
Page 122 General technical description Continued Pos. Symbol Function/meaning Switch EOC on/off S transfer tube switch over: Snail, hare and auto Reset the trip" day counter This symbol is displayed in the following menus: Operating data, user settings AP21_046_1602EN...
Page 123 General technical description Instruments in the HOME menu AP21_046_1602EN Pos. Display Function/meaning Cooling water temperature [°C], The cooling water temperature is displayed. analogue and digital Engine speed [rpm], The engine speed is displayed. analogue and digital Hydraulic fluid temperature [°C], The hydraulic fluid temperature is displayed.
Page 124 General technical description Symbols in the HOME menu AP21_047_1602EN 1 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. AP21_047_1602EN...
Page 125 CAN bus 1. This symbol flashes and is displayed in red if a fault has occurred in the CAN bus (CAN1 = connection between controller and display). You need to have the fault rectified by a Putzmeister service techni cian. AP21_047_1602EN...
Page 126 CAN bus 2. This symbol flashes and is displayed in red if a fault has occurred in the CAN bus (CAN2 = connection between engine control unit and controller). You need to have the fault rectified by a Putzmeister service technician. Sensors This symbol is displayed in grey if no fault has occurred in the magnetic switches (see the Magnetic switches distributor casing"...
Page 127 General technical description EMERGENCY STOP This symbol is displayed in grey if no EMERGENCY STOP button has been pressed or if the EMERGENCY STOP has been acknowledged. This symbol flashes and is displayed in red if an EMERGENCY STOP button has been pressed. Agitator safety cutout (RSA) This symbol is displayed in grey if the agitator safety cutout has not been pressed or if the agitator safety cutout has been...
Page 128 General technical description This symbol is displayed in grey if EOC is switched off. This symbol is displayed in green if EOC is switched on. Delivery rate This symbol is displayed in grey if the concrete pump is switched off. The delivery rate is displayed in numbers if the concrete pump is switched on and the Forward pumping"...
Page 129 General technical description Vibrator This symbol is displayed in grey if the vibrator is switched off. This symbol is displayed in white if the concrete pump and the vibrator are switched off but the Pump off − 0 − Vibrator on" toggle switch has been switched to Vibrator on"...
Page 130 General technical description Expanded HOME The HOME menu is the main menu. Data and main instruments are menu displayed here. Function buttons in the expanded HOME menu AP21_029_1511EN 1 Pos. Display Function/meaning The last selected start menu is opened by pressing Button button (1).
Page 131 General technical description Instruments in the expanded HOME menu AP21_029_1511EN 2 Pos. Display Function/meaning Cooling water tempera The cooling water temperature is displayed. ture [°C], analogue Engine oil pressure [bar], The engine oil pressure is displayed. analogue Engine speed [rpm], ana The engine speed is displayed.
Page 132 General technical description All symbols in the menu bar Note You can find a description of all symbols in the menu bar, regardless of the current menu, in the section All symbols in the menu bar". Symbols in the expanded HOME menu AP21_029_1511EN 3 Note You can find a description of the symbols in the expanded HOME...
Page 133 General technical description Software information In this menu, you can read off the software versions of the control systems. Display Function/meaning Putzmeister Small Pump Control Generation 2 Controller Display V100 Version 1.0.0 AP21_030_1511EN 1 Pos. Display Function/meaning The software versions of the control systems are dis Software versions played.
Page 134 General technical description Operating data The operating data for the machine are displayed in two tables in this menu, with the total values in the total" table on the left and the current values in the trip" table on the right. AP21_031_1511EN 1 Pos.
Page 135 General technical description AP21_031_1511EN 2 Continued Pos. Display Function/meaning The current stroke time 2 is displayed. Stroke time 2 [s] Stroke time 2: For example, the time required for drive piston 2 to move towards the water box. The current stroke time 1 is displayed. Stroke time 1 [s] Stroke time 1: For example, the time required for drive piston 1 to move towards the cylinder base.
Page 136 General technical description Fault memory The fault codes for the most recent faults are displayed in this menu. AP21_032_1511EN 1 Pos. Display Function/meaning Fault The fault code is displayed. The last selected HOME menu can be opened by Momentary contact switch pressing button (2).
Page 137 General technical description User settings In this menu, you can set setpoint values for the pump output and the fill level of the delivery cylinders and compare them with the actual values that have been achieved. The delivery rate can be calculated with the operating data specified above.
Page 138 General technical description Function buttons in the user settings menu AP21_033_1511EN 1 Pos. Display Function/meaning The last selected HOME menu can be opened by Momentary contact switch pressing button (1). Parameters are selected by pressing up or down on the direction button (2). Direction key The value of the parameter is set by pressing left or right on the direction button (2).
Page 139 General technical description AP21_033_1511EN 2 Pos. Display Function/meaning The specified pump output or the fill level of the deliv Setpoint values ery cylinders is displayed. The pump output or fill level of the delivery cylinders that has been achieved is displayed. Actual value (adjustable) The two parameters are used in the calculation of the output [m...
Page 140 General technical description Continued Pos. Display Function/meaning In the event of a fault: The setpoint and actual values for the stroke time are Stroke time [s] displayed. In the event of a fault: The simulated engine speed is displayed in numbers. Engine speed [rpm], digital Fill level of the delivery cyl The setpoint and actual values for the Fill level of the...
Page 141 General technical description Lubrication You can begin a manual lubrication cycle or set the number of strokes until the next lubrication in this menu. Parameters such as the number of strokes performed since the last lubrication and the number of strokes until the next lubrication are displayed. Function buttons in the lubrication menu AP21_048_1602EN 1 Pos.
Page 142 General technical description All symbols in the menu bar AP21_048_1602EN 2 Pos. Symbol Function/meaning Back to the start menu This symbol is displayed regardless of the current menu. The symbol has no function in the HOME menu. Manually activate a lubrication cycle. Reset to the factory settings.
Page 143 General technical description AP21_048_1602EN 3 Pos. Display Function/meaning The number of strokes until the next lubrication is Number of strokes, analogue displayed. The number of strokes until the next lubrication is Number of strokes, digital displayed in numbers. The number of strokes performed since the last Number of strokes, digital lubrication is displayed in numbers.
Page 144 General technical description Inputs and outputs This menu is used to display the number of active inputs and out puts. It also allows you to reset the position values for the S transfer tube, for example after installing the resolver. Function buttons in the inputs and outputs menu AP21_049_1602EN 1 Pos.
Page 145 General technical description All symbols in the menu bar AP21_049_1602EN 2 Pos. Symbol Function/meaning Back to the start menu This symbol is displayed regardless of the current menu. The symbol has no function in the HOME menu. The position values for the S transfer tube are reset to the factory settings.
Page 146 General technical description AP21_049_1602EN 3 Pos. Display Function/meaning An overview of all inputs is displayed. The active IN = inputs, analogue inputs are displayed in green. IN = inputs, digital The active inputs are also displayed in numbers. An overview of all outputs is displayed. The active OUT = outputs, analogue outputs are displayed in green.
Page 147 General technical description 3.6.3 Ergonic Output Con- The Ergonic Output Control (EOC) enables you to save the selected trol (EOC) engine speed. You can switch the Ergonic Output Control on and off using the SPC display unit. HOME menu AP21_034_1512EN 1 Pos.
Page 148: Ergonic Output Control (Eoc)
General technical description Special features of Ergonic Output Control Switch Ergonic Output If the display is malfunctioning or de−energised or a CAN bus fault Control on/off has occurred, the Ergonic Output control will be switched on auto matically. If the display is functioning properly, the Ergonic Output Control will be switched off after the control system is restarted (switching on the ignition).
Page 149 General technical description Ergonic Output Control The factory−set engine speed replaces any saved EOC speed. switched off If the Ergonic Output Control is switched off, the pump control sys tem will behave in the following way: Concrete pump start The engine will be started up at the factory−set engine speed if the current engine speed when the concrete pump is started up is smaller than the preset engine speed.
Page 150: Fuse Box
General technical description 3.6.4 Fuse box The fuse box is located underneath the OPS/EGD control cabinet". The toggle switch for Engine protection override" is located at the side on the right and can be used to continue running the engine in emergency operation for a short time.
Page 151: Cable Remote Control
General technical description 3.6.5 Cable remote control The most important control functions for the pump are gathered together on the cable remote control, so that you can control the operation of the pump from here. AP02_905_1304EN 1 Operating/control element Meaning/function Comments Momentary contact switch EMERGENCY STOP...
Page 152 General technical description Special features of the cable remote control Starting up the pump The red EMERGENCY STOP activated" indicator lamp on the after EMERGENCY control cabinet lights up and the green Pump running" indicator STOP lamp flashes if you have pressed the EMERGENCY STOP button. You can only restart the pump as described below: −...
Page 153: Emergency Stop Button
General technical description 3.6.6 EMERGENCY STOP EMERGENCY STOP buttons are fitted to the following machine com button ponents: − the cable remote control − the right hand side of the machine, near the operating elements. Caution Familiarize yourself with the positions of the EMERGENCY STOP but tons on your machine.
Page 154 General technical description The following actions are triggered when you press one of the EMERGENCY STOP buttons: − the EMERGENCY STOP symbol lights up red on the EPS/EGD control cabinet, − variable main pumps swing back, the delivery pistons come to a halt, −...
Page 155: Agitator Safety Cutout (Rsa)
General technical description 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. This causes the agitator to halt and the pressure to be dumped from the accumulator, i.e.
Page 156 General technical description Note If the evaluation device becomes defective, the agitator safety cutout is triggered and the agitator, transfer tube and concrete pump are stopped. Therefore, always check that the agitator safety cutout is working properly before using the pump. The LED on the evaluation device has the following display: The green LEDs flash for 8 seconds during the initialization pro cess.
Page 157 General technical description 3.6.8 Magnetic switches The distributor casing for the magnetic switches is located beneath distributor casing the control cabinet. AP02_853_1202EN 1 Belongs Control element Meaning/Function with no.: Yellow LED Magnetic switch (rod side), drive cylinder II Yellow LED Magnetic switch (rod side), drive cylinder I Female connector Not assigned...
Page 158 Distributor casing status lights up continuously The distributor casing is ready for operation. does not light up The Putzmeister operating sys tem is not supplied with a volt age. Note Additional LEDs are located on the magnetic switch connector (see page 3 72).
Page 159 General technical description Stroke correction Electronic stroke correction on this machine takes place as required. As soon as the piston side magnetic switch in drive cylinder 1 is trig gered, it always resets the set time to zero. If this magnetic switch is no longer triggered, the set time (e.g.
Page 160 General technical description 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. 20500406 Designation Green and yellow LEDs Connector Magnetic switch Note The yellow LED indicates the status of the magnetic switch, the...
Page 161 General technical description 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...
Page 162 General technical description 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.
Page 163 General technical description 3.7.1 Output controller The output controller (1) is used to open/close an adjustment valve, so that the output is increased or reduced. If the output controller (1) shows min", the delivery cylinders remain stationary − the concrete pump is switched off.
Page 164 General technical description 3.7.2 Pump control system The hydraulic control valves are built into the pump control system. They are only for emergency manual operation of the machine when the control system fails. AP02_941_1311EN 1 Designation Emergency operation − transfer tube Drive cylinder emergency operation Special features of the pump control system Emergency operation...
Page 165 General technical description 3.7.3 Pressure gauge The hydraulic pressure of the hydraulic pump is shown on the pressure gauge. AP02_063_0308EN 1 3.7.4 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...
Page 166 General technical description 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.
Page 167 General technical description 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 is hydraulically powered, and runs once the machine is switched on. The hydraulic fluid radiator cools the diesel engine and the hydraulic fluid circuit of the concrete pump.
Page 168 General technical description 3.8.2 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.
Page 169 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.
Page 171 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...
Page 172 Starting up 4.1.2 Functional fluids Making ready for operation also includes topping up the functional fluids. 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...
Page 173 Starting up 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 "...
Page 174 Starting up 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.
Page 175 Starting up 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 "...
Page 176 Starting up Test run Depending on the machine’s equipment, the following sequence of actions must be carried out for the test run: − Opening the ventilation flap − Open side flaps − 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.
Page 177 Starting up 4.2.1 Switching on Before switching on the machine, you must set up the machine cor the machine 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".
Page 178 Starting up Note To operate the machine locally, the Local control" replacement con nector must remain plugged into the Local control − remote control" socket on the control cabinet. AP13_109_1511EN 2 Designation Local control" replacement connector Plug in the Local control" replacement connector. "...
Page 179 Starting up 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.
Page 180 Starting up 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.
Page 181 Starting up 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.
Page 182 Starting up 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.
Page 183 Starting up AP13_075_1202EN 1 Designation Transponder (in the grille) LED, green and red Acknowledge agitator or agitator safety cutout on the EPS/EGD control cabinet Reading head (on the hopper − example illustration) Open the grille with the concrete pump running. "...
Page 184 Starting up 4.3.4 Acknowledge the agi- The agitator is secured against unexpected restarts. When the ma tator safety cutout chine 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.
Page 185 Starting up AP13_076_1202EN 1 Designation Acknowledge agitator or agitator safety cutout on the EPS/EGD control cabinet Actuate the Acknowledge agitator or agitator safety cutout" " toggle switch on the EPS/EGD control cabinet. 4 — 15 AP13_076_1202EN...
Page 186 Starting up 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.
Page 187 Starting up 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.
Page 188 Starting up 4.3.6 Agitator The agitator hopper grille must always be closed when the pump is in operation. AP13_110_1511EN 1 Designation Agitator On − agitation direction away from the delivery cylinder (1a) Agitator Off Agitator On − agitation direction towards the delivery cylinder (1b) Actuate the toggle switch on the control cabinet and check the "...
Page 189 Starting up 4.3.7 Vibrator The vibrator is electrically driven so an electrical connection must first be made between it and the control cabinet. 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.
Page 190 Starting up 4.3.8 Switching off You can shut down the machine after completing the function the machine checks. When you shut down the machine, you must perform the following tasks: Switch off the pump at the control cabinet. " Switch off all power consumers. "...
Page 191 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...
Page 193 Transport, setting up and connection 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 F 80 chassis can travel on public highways. −...
Page 194 Transport, setting up and connection 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).
Page 195 Transport, setting up and connection 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. AP06_003_1007EN 2 4 lifting eyes AP06_003_1007EN...
Page 196: Static Base Structure
Transport, setting up and connection 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 F 8 chas...
Page 197 Transport, setting up and connection 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 F 80 chassis. Note Stationary concrete pumps can only be driven on public roads if they have the appropriate approval.
Page 198 Transport, setting up and connection 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 50 km. See the spare parts sheet for the tightening torques.
Page 199 Transport, setting up and connection 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 "...
Page 200: Hand Signals For Driving
Transport, setting up and connection 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.
Page 201 Transport, setting up and connection 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.
Page 202: Requirements For The Set-Up Site
Transport, setting up and connection 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 "...
Page 203 Transport, setting up and connection 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.
Page 204 Transport, setting up and connection 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 "...
Page 205 Transport, setting up and connection 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 "...
Page 206: Setting Up
Transport, setting up and connection Setting up The machine must be level. Pay attention to the section headed Requirements for the set up site". Drive the machine to the inspected set up site. " AP06_070_1403EN 1 Initial situation Pos. Designation Support wheel Support leg with support foot Use chocks to secure the machine against rolling.
Page 207 Transport, setting up and connection AP06_070_1403EN 2 Lowering the drawbar at the front Wind up the support wheel in order to lower the drawbar. " AP06_070_1403EN...
Page 208 Transport, setting up and connection AP06_070_1403EN 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 until the machine is level once it is "...
Page 209 Transport, setting up and connection AP06_070_1403EN 4 Raising the machine and supporting at the front Use the support wheel to raise the machine until the forward " support feet can be extended to exactly the same extent as the rear feet. Place timber blocks or other suitable material beneath the for "...
Page 210 Transport, setting up and connection AP06_070_1403EN 5 Machine set up correctly Wind up the support wheel. " å The wheels are no longer in contact with the ground when the machine is supported. Note Sudden pulsations from the delivery line may be transmitted to the machine under extreme operating conditions (e.
Page 211: Stationary Delivery Line
Transport, setting up and connection 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.
Page 212: Danger Zone
Transport, setting up and connection 5.5.1 Danger zone 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.
Page 213: Instructions For Laying The Line
Transport, setting up and connection 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.
Page 214 Transport, setting up and connection 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.
Page 215: Fastening
Transport, setting up and connection 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.
Page 216 Transport, setting up and connection Fixed point A fixed point is a 1 − 2 m 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.
Page 217 Transport, setting up and connection 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.
Page 218 Transport, setting up and connection 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 30 kg per metre of continuous pipe) when the pump is switched off.
Page 219: Delivery Line System
Transport, setting up and connection 5.5.4 SK delivery line When laying Putzmeister SK delivery pipes, maintain a gap of 4 mm 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.
Page 221 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...
Page 223: Pumping Operations
Pumping operations 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: −...
Page 224: Remote Control
Operation 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 can be actuated unintentionally.
Page 225: Hand Signals For Pumping
Pumping operations 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.
Page 226 Pumping operations 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...
Page 227: Filling The Machine With Fuel
Pumping operations Filling the machine Your machine is driven by a diesel engine. The fuel tank is built into with fuel the superstructure, its filler pipe is on the top. You may refuel the machine, once it is switched off, through the filler pipe. Note Refill the fuel tank in good time, as otherwise you will have to bleed the fuel line to the diesel engine.
Page 228: Considering Concrete Properties
Pumping operations 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.
Page 229: Filling The Agitator Hopper
Pumping operations 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.
Page 230: Starting Pumping
Pumping operations 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.
Page 231: Pumping
Pumping operations 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 4 minutes after they are added. Pour the concrete from the truck mixer, silo, etc into the agitator "...
Page 232: Monitoring
Pumping operations 6.7.1 Monitoring The displays of the monitoring instruments must be kept under observation during pumping operations. 10301100 Designation Vacuum meter Hydraulic fluid temperature gauge 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.
Page 233 Pumping operations 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.
Page 234: Blockages
Pumping operations 6.7.2 Blockages 11000601 Designation Wedged aggregate Cement paste 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 −...
Page 235: Breaks In Pumping
Pumping operations 6.7.3 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: −...
Page 236: Engine
Pumping operations 6.7.4 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.
Page 237 Pumping operations Cooling 10600200 Change the water frequently if the temperature continues " to rise. 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.
Page 238: Restarting
Pumping operations 6.7.6 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. "...
Page 239: Emergency Operation - Pump Function
Pumping operations 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. Note For the location of the pump control system, refer to the overview at the start of the chapter General technical description".
Page 240 Pumping operations Operating the OPS pump control system Drive cylinder In order to be able to move the piston to the cylinder end position, emergency operation operate the drive cylinder emergency operation (2). Emergency operation − In order to be able to switch over the transfer tube, keep the drive transfer tube cylinder emergency operation (2) pressed, while at the same time operating the transfer tube emergency operation (1).
Page 241: Cleaning
Pumping operations 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.
Page 242 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.
Page 243 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.
Page 244: Preparations For Cleaning
Pumping operations 6.9.1 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 other accessories 10003401 Sponge pig...
Page 245 Pumping operations 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.
Page 246 Pumping operations 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.
Page 247 Pumping operations 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. AP07_041_9712EN 1 T−delivery pipe with wash−out port Wash−out port lid Danger...
Page 248 Pumping operations 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 water cleaning cement bags prevent the washing water penetrating the concrete, flushing the concrete out and causing blockages. 10003501 Rolled−up cement bags Roll up 1 −...
Page 249 Pumping operations 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.
Page 250: Delivery Line
Pumping operations 6.9.2 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.
Page 251 Pumping operations Overview of the cleaning procedures for the stationary delivery line Leavings from Delivery line Method of cleaning Compressed air Water under pressure Horizontal line Suction cleaning Compressed air only with special special Water under pressure Riser equipment Suction cleaning Compressed air only with special...
Page 252 Pumping operations 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.
Page 253 Pumping operations 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.
Page 254 Pumping operations 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 "...
Page 255 Pumping operations 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.
Page 256 Pumping operations Introducing the wash−out sponge AP07_046_9712EN 1 Prepared pipe section for cleaning 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.
Page 257: Hopper, Delivery Cylinder And S Transfer Tube
Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç 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 "...
Page 258 30000500 Hoisting the concrete away Caution You may only hoist a maximum of 0.5 m concrete (approxi mately 1200 kg) using the Putzmeister leavings sheet. Hoist away the concrete in the Putzmeister leavings sheet. " AP07_047_9904EN...
Page 259 Pumping operations Spray out delivery cylinder Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç Ç...
Page 260 Pumping operations 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...
Page 261 Pumping operations 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 2 mm, if not the transfer tube must be readjusted. Maintenance card: Adjusting the S transfer tube AP07_047_9904EN 4 Transfer tube Thrust ring...
Page 262 Pumping operations 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 AP07_068_1007EN 1 Designation S transfer tube Areas that must be cleaned Pressure connection...
Page 263 Pumping operations 6.9.4 Post-cleaning Once the delivery line, hopper, delivery cylinders and S transfer procedure tube have 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.
Page 264 Pumping operations Clean all seals and the seal seats. " Grease the seals before replacing them. " Clean the remaining parts of the machine by rinsing down " with water. At the lubrication point provided, grease all of the bearing "...
Page 265: Measures For Preserving The Value Of Concrete Pumps
Operation 6.10 Measures for If you are placing concrete pumps or placing booms into storage preserving the value for more than four weeks, you must carry out the following measures of concrete pumps in order to preserve their value. Carry out these measures at least and placing booms every 3 months.
Page 266 Operation Assembly Action Lubricate the arm assembly. Detach the end hose. Boom Grease all exposed piston rods with Vaseline. Check the function of hose reels on machines larger than an M52: Support Fully extend the front support legs 10 times. Grease all exposed piston rods with Vaseline.
Page 267 Putzmeister will not accept warranty claims for engine damage and operating errors that result from a failure to switch off the engine according to the instructions.
Page 269 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".
Page 271 Maintenance 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.
Page 272 Maintenance 7.1.2 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 Engine start up/engine off fully functional General All operating elements...
Page 273 Maintenance 7.1.3 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 no cement−coloured oil and grease Transfer tube Bearings and seal on the pressure mixture or slurry cement may escape connection...
Page 274 Maintenance 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.
Page 275 Maintenance 7.2.2 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.
Page 276 Maintenance Assembly Activity / Maintenance card Extend and retract all cylinders to the stop (expel water) Check the condition of the piston rods Check the seals on the piston rods Core pump 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...
Page 277 Maintenance Residual risks during maintenance, inspection and repair work 7.3.1 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 not worn. Always wear your personal protective equipment during maintenance, inspection and repair work.
Page 278 Maintenance 7.3.4 Residual risks During maintenance, inspection and repair work, there are particular risks of an accident, because for certain activities, protective devices must be removed, for example. There follows a list of residual risks in particular, which may be present during maintenance, inspection and repair work.
Page 279 Maintenance Danger Risk of injury from pressurised hydraulic fluid. Put the machine out of service 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.
Page 280 Maintenance General tightening Tightening torques depend on bolt grade, thread friction and bolt torques head bearing area. The values given in the following tables are for guidance. These values should only be used if no other values are specified in the relevant chapters of the Operating Instructions or in spare parts sheets.
Page 281 Maintenance 7.4.2 Flared screwed joint, After each time the joint is undone, the union nut must be tightened reassembly again securely without excessive force. Flared screwed joints External diam- [Nm] External diam- [Nm] eter / Type eter / Type * RAD = pipe external diameter = tightening torque Note Hold threaded connection fast against turning with wrench.
Page 282 Maintenance Functional fluids This section lists all the functional fluids used in your machine. Caution Never use hydraulic fluids or lubricants with additives such as molybdenum. Such additives can attack the bearings. 7.5.1 Hydraulic fluid The hydraulic system is filled with: −...
Page 283 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.
Page 284 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.
Page 285 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).
Page 286 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.
Page 287 Maintenance 7.6.1 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 parts Viscosity grade, sheet CLP 220 CLP 220 CLP 220 NLGI Class Material no.
Page 288 Maintenance 7.6.2 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...
Page 289 7.6.3 Hydraulic fluids Category Mineral oil Synthetic ester Aqueous solutions Type HEES Classification 51502 6743/0 Requirement 51524 Part 2 6743 Part 4 VDMA 24318 24568 24317 / 24320 Others 7th Luxembourg Report Viscosities 51519 3448 /s ISO VG 15_C to +80_C 10_C to +90_C 0_C to +95_C 10_C to +80_C...
Page 291 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...
Page 293 Maintenance card 00−001 Page 1 of 2 00–001 Visual checks This maintenance card describes visual checks that you must carry out before commencing any maintenance work. 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.
Page 294 Maintenance card 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. "...
Page 295 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 "...
Page 296 Maintenance card 03−002 Page 2 of 2 WK03_002_1109EN...
Page 297 Maintenance card 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.
Page 298 Maintenance card 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. "...
Page 299 Maintenance card 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.
Page 300 Maintenance card 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.
Page 301 Maintenance card 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.
Page 302 Maintenance card 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.
Page 303 Maintenance card 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.
Page 304 Maintenance card 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.
Page 305 Maintenance card 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.
Page 306 Maintenance card 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 "...
Page 307 Maintenance card 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.
Page 308 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.
Page 309 Maintenance card 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 (>...
Page 310 Maintenance card 04−013 Seite 4 von 6 Changing WK04_013_1109EN 2 Designation Filter element 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.
Page 311 Maintenance card 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 O rings and other seals on the filter elements and replace them if damaged.
Page 312 Maintenance card 04−013 Seite 6 von 6 WK04_013_1109EN...
Page 313 No further maintenance cards required. No special tools required. Note You must rectify damage to the delivery pistons immediately. Putzmeister accepts no warranty claims for damage to the machine resulting from failure properly to observe the maintenance regula tions. Danger Secure the working area.
Page 314 Maintenance card 06−023 Page 2 of 6 You will have to start and stop the machine a number of times as you replace the delivery pistons . The operations necessary for this are described below and must be carried out conscientiously. Shutting down Proceed as follows to shut down the machine: the machine...
Page 315 Maintenance card 06−023 Page 3 of 6 Piston replacement Pistons are replaced from the water box. Danger Always shut the machine down before you reach into the water box. 10600301 Piston rod flange Fastening bolts Securing wire Delivery piston Spacer flange Shut the machine down.
Page 316 Maintenance card 06−023 Page 4 of 6 Removing a piston 10600701 Fastening bolts Remove the wire clips from the fastening bolts and remove the " bolts from the spacer flange. Shift the unbolted delivery piston away from the spacer flange, "...
Page 317 Maintenance card 06−023 Page 5 of 6 Start the machine up. " Set the toggle switch on the control cabinet to reverse " pumping. Switch the concrete pump on at a very low output. " å The delivery piston is withdrawn completely from the delivery cylinder.
Page 318 Maintenance card 06−023 Page 6 of 6 Start the machine up. " Switch the concrete pump on at a very low output. " å The new delivery piston is pushed very slowly into the delivery cylinder. Switch the pump off before the fastening bolts for the delivery "...
Page 319 Maintenance card 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.
Page 320 Maintenance card 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...
Page 321 Maintenance card 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. "...
Page 322 Maintenance card 07−069 Page 4 of 6 Replacing the transfer tube bearing gasket 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.
Page 323 Maintenance card 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 "...
Page 324 Maintenance card 07−069 Page 6 of 6 WK07_069_1109EN...
Page 325 Maintenance card 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.
Page 326 Maintenance card 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.
Page 327 Maintenance card 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. "...
Page 328 Maintenance card 07−070 Page 4 of 16 Overview WK07_070_1109EN 1 Designation Pulling bore for ball cup Ball cup Hydraulic port Plunger cylinder Retaining plate Retaining plate fastening bolts Switch lever Clamping bolts with nuts Disc Switching shaft Hexagon nut Flanged bearing Pulling bore for flanged bearing (two diagonally opposite each other) Fastening bolt for flanged bearing (covered)
Page 329 Maintenance card 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. "...
Page 330 Maintenance card 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.
Page 331 Maintenance card 07−070 Page 7 of 16 WK07_070_1109EN 3 Designation Plunger cylinder Locking plate Ball cup 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.
Page 332 Maintenance card 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 "...
Page 333 Maintenance card 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).
Page 334 Maintenance card 07−070 Page 10 of 16 WK07_070_1109EN 6 Designation Fastening bolt Pulling bores (two, diagonally opposite each other) Flanged bearing Unscrew the fastening bolt (1) from the flanged bearing (3). " Attach suitable lifting gear to the S transfer tube. "...
Page 335 Maintenance card 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 "...
Page 336 Maintenance card 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.
Page 337 Maintenance card 07−070 Page 13 of 16 Wear sleeve on flanged bearing and collared washer WK07_070_1109EN 10 Designation Wear sleeve on the flanged bearing Flanged bearing Collared washer Bore Bend the tab (5) on the collared washer (3) downwards. " Place the collared washer (3) on the flanged bearing (2) so that "...
Page 338 Maintenance card 07−070 Page 14 of 16 Mounting the switch lever WK07_070_1109EN 11 Designation Switch lever Switching shaft Switching shaft bearing (flanged bearing) Groove Wear sleeve Flattened tooth Notch Grease the teeth on the switch lever (1) and the switching shaft "...
Page 339 Maintenance card 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. "...
Page 340 Maintenance card 07−070 Page 16 of 16 WK07_070_1109EN...
Page 341 Maintenance card 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.
Page 342 Maintenance card 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.
Page 343 Maintenance card 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...
Page 344 Maintenance card 07−071 Page 4 of 14 Overview WK07_071_1109EN 1 Designation Plunger cylinder Switch lever Clamping bolts with nuts Switching shaft Hexagon nut Fastening bolts for spectacle wear plate WK07_071_1109EN...
Page 345 Maintenance card 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).
Page 346 Maintenance card 07−071 Page 6 of 14 Replacing the inter- mediate rings WK07_071_1109EN 3 Designation Transition liner Intermediate ring Screw plug Lubrication nipples Grease gun WK07_071_1109EN...
Page 347 Maintenance card 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 "...
Page 348 Maintenance card 07−071 Page 8 of 14 WK07_071_1109EN 5 Designation Intermediate ring O−rings 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). "...
Page 349 Maintenance card 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 "...
Page 350 Maintenance card 07−071 Page 10 of 14 É É É É É É É É É É É É É É É É É É É É É É É É WK07_071_1109EN 7 Designation Fastening bolts on the left and right Spectacle wear plate Fastening bolts at the top and bottom Intermediate ring...
Page 351 Maintenance card 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.
Page 352 Maintenance card 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.
Page 353 Maintenance card 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. "...
Page 354 Maintenance card 07−071 Page 14 of 14 WK07_071_1109EN...
Page 355 Maintenance card 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.
Page 356 Maintenance card 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.
Page 357 Maintenance card 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...
Page 358 Maintenance card 07−072 Page 4 of 8 S transfer tube vari- ants WK07_072_1109EN 1 Designation S transfer tube with bolted switching shaft 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.
Page 359 Maintenance card 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.
Page 360 Maintenance card 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.
Page 361 Maintenance card 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.
Page 362 Maintenance card 07−072 Page 8 of 8 WK07_072_1109EN...
Page 363 Maintenance card 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.
Page 364 Maintenance card 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.
Page 365 Maintenance card 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...
Page 366 Maintenance card 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.
Page 367 Maintenance card 07−073 Page 5 of 8 WK07_073_1109EN 1 Designation Welds Tube outlet 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. "...
Page 368 Maintenance card 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 Caution removed...
Page 369 Maintenance card 07−073 Page 7 of 8 Fitting a wear sleeve WK07_073_1109EN 2 Designation Wear sleeve 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. "...
Page 370 Maintenance card 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) WK07_073_1109EN...
Page 371 Maintenance card 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.
Page 372 Maintenance card 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.
Page 373 Maintenance card 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...
Page 374 Maintenance card 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 "...
Page 375 Maintenance card 07−074 Page 5 of 6 WK07_074_1109EN 1 Designation Thrust ring 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.
Page 376 Maintenance card 07−074 Page 6 of 6 WK07_074_1109EN...
Page 377 Maintenance card 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.
Page 378 Maintenance card 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.
Page 379 Maintenance card 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.
Page 380 Maintenance card 07−075 Page 4 of 14 Prestressing the S First, prestress the S transfer tube. transfer tube Shut the machine down. " WK07_075_1109EN 1 Designation Spectacle wear plate Wear ring S transfer tube Thrust ring Hexagon nut Retaining plate Switch lever Clamping bolts Note...
Page 381 Maintenance card 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.
Page 382 Maintenance card 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.
Page 383 Maintenance card 07−075 Page 7 of 14 WK07_075_1109EN 3 Designation Plunger cylinder Ball cup 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...
Page 384 Maintenance card 07−075 Page 8 of 14 WK07_075_1109EN 5 Designation 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. "...
Page 385 Maintenance card 07−075 Page 9 of 14 Spectacle wear plate with sample markings WK07_075_1109EN 6 Designation Packing washer too thin Packing washer too thick Optimum packing washer To decrease the swing angle of the S transfer tube by 4 mm, the fitted packing washer must be replaced by one which is 2 mm thicker.
Page 386 Maintenance card 07−075 Page 10 of 14 WK07_075_1109EN 7 Designation Plunger cylinder 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.
Page 387 Maintenance card 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. WK07_075_1109EN 8 Designation Ball cup Packing washer Remove the hexagon ball cup (1) along with the packing "...
Page 388 Maintenance card 07−075 Page 12 of 14 Allow the S transfer 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 "...
Page 389 Maintenance card 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 E Compare the two measurements. "...
Page 390 Maintenance card 07−075 Page 14 of 14 WK07_075_1109EN...
Page 391 Maintenance card 07−078 Seite 1 von 2 07–078 Resolver on the switching This maintenance card describes how to fit the resolver on the shaft switching shaft. Note There are specific risks of accidents associated with maintenance, inspection and repair work. For this reason, read the chapter Safety regulations"...
Page 392 Maintenance card 07−078 Seite 2 von 2 WK07_078_1304EN 1 Designation Connecting cable Resolver Magnetic sensor Switch lever Switch cylinders Fit the resolver (2) as shown in the graphic. " å The resolver is located in its electrical middle position. Maintain the reacting distance a" (a = 8 +/− 4 mm). "...
Page 393 Wartungskarte 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.
Page 394 Wartungskarte 08−007 Page 2 of 2 WK08_007_1109EN 1 Plate indicating the lubrication intervals Centralized lubrication nipple strip 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.
Page 395 Maintenance card 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.
Page 396 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.
Page 397 Maintenance card 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.
Page 398 If the operating pressure is higher than 130 bar, you must ask Putzmeister what the minimum wall thickness is. WK10_007_1109EN...
Page 399 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.
Page 400 Maintenance card 10−007 Page 6 of 6 Graph Minimum wall thickness as a function of operating pressure High pressure Maximum delivery pressure WK10_007_1109EN...
Page 401 Maintenance card 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.
Page 402 Maintenance card 10−044 Page 2 of 2 Inspecting two–layer Inspect two−layer delivery pipes and delivery line elbows delivery pipes and (DN 125, max. concrete pressure 85 bar) as follows: delivery line elbows Visual inspection for cracks. Replace in case of crack "...
Page 403 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.
Page 405 Index of key words Chassis Control devices Crawler track, Drive cylinder emergency operation, 6 17 Abbreviations, Description of the functions, 3 10 G 15 Electrical, 3 20 F 8, Accessories and attachments, 2 14 Emergency operation − transfer tube, F 25, After Sales Service personnel, Defini- 6 17 F 80,...
Page 406 Index of key words Delivery line Electromagnetic compatibility, Vibrator, 4 19 Cleaning, 6 28 Electrostatic charging, Function description, Agitator, 2 24 3 14 Measuring the wall thickness, 7 131 EMC, Functional fluids, 7 12 Measuring the wall thickness (Machi Emergency operation, Fuse box, 3 62 3 62...
Page 407 Index of key words Setting up, 5 14 Switching off, 4 20 Icons, Switching on, Noise emissions, 2 58 Machine operator Impermissible end hose, 2 12 Definition of terms, Impermissible working area, Responsibility of the machine operator, 2 13 2 15 Operating Instructions, 2 16 Inputs and outputs menu, Symbols in...
Page 408 Index of key words Responsibility of the machine opera- Space requirement, For truck mixers, Protective goggles, 2 19 tor, 2 15 5 11 Safety footwear, 2 18 Safety harness, 2 19 Restrictions, Cold weather, SPC, SPC display, 2 39 3 27 Safety helmet, 2 18 Retesting (safety inspection),...
Page 409 Index of key words Technical terms, Use contrary to designated use, Vibrator, 3 41 G 15 2 11 Accessories and attachments, 2 14 SPC display unit, Temperatures, 3 27 3 17 Climbing the placing boom, 2 13 Operating elements, 3 27 Restrictions, 2 39 Exclusion of liability,...
Page 411 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...
Page 413 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...
Page 414 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...
Page 415 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...
Page 416 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...
Page 417 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 —...
Page 418 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...
Page 419 Glossary G–2 Key to the symbols for concrete pumps G–2.1 General 3701 Increase/reduce output using rotary controller 5001 Agitator, hopper 3702 Increase/reduce output using toggle switch 5002 Agitator clockwise rotation 3703 Increase output 5003 Agitator anticlockwise rotation 3704 Reduce output 5004 Hopper empty 3705...
Page 420 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...
Page 421 Glossary 12013 Potentiometer 12042 Lock 12014 Off − On 12043 2nd level 12015 12044 Circuit 1 12016 12045 Circuit 2 12017 Fast (e.g. acceleration) 12046 Circuits 1+2 12018 Normal (e.g. acceleration) 12047 High−pressure limit 12019 Compressor 12048 Flap/closure closed 12020 Compressor On −...
Page 422 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...
Page 423 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...
Page 424 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...
Page 425 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...
Page 426 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...
Page 427 Glossary G–3 Abbreviations and technical terms 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. → 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.
Page 428 Automatic vehicle−specific control of fuel consumption → Ergonic Output Control → 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.
Page 429 Glossary → 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...
Page 430 Operating equipment Battery, filters → One−Side−Support → Putzmeister Electronic Documentation PEDOC 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.
Page 431 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.
Page 432 Glossary Service operation The Pumping operations − Service operations" toggle switch on the 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".
Page 433 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.
Page 434 Glossary BP14_002_0501EN...

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