Putzmeister BSA 1409 D4 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.

19−03−04

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

BSA 1409 D4

210110932

E Putzmeister Concrete Pumps GmbH 1994

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Page 1 Translation of the original Operating Instructions Stationary concrete pump BSA 1409 D4 Machine no. 210110932 19−03−04 The paper on which this document is printed is 100% chlorine free E Putzmeister Concrete Pumps GmbH 1994...
Page 2 Carrwood Road PMUK GB−Chesterfield +44−1246−26 00 77 www.putzmeister.co.uk Derbyshire S41 9QB Türkiye +90−282−735−1000 pm@putzmeister.com.tr Putzmeister Makine Sanayi ve Tic. A. 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 pmr@putzam.com...
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 4 BP00_030_0911EN...
Page 5 Table of contents Table of contents Guide to the Operating Instructions Foreword ......... . . 1 —...
Page 6 Table of contents 2.3.6 Impermissible end hose ....... 2.3.7 Impermissible working area .
Page 7 Table of contents 2.11.2 Supporting ground ........2.11.3 Corner bearing loads .
Page 8 Table of contents General technical description Overview ......... . . 3 —...
Page 9 Table of contents Hydraulic control devices ......3 — 99 3.7.1 Water pump lever .
Page 10 Table of contents Transport, setting up and connection Transport ......... . . 5 —...
Page 11: Table Of Contents
Table of contents Pumping operations Preconditions ........6 —...
Page 12 Table of contents Glossary G–1 Symbols for concrete pumps in accordance with German Mechanical Engineering Association Standard (VDMA 24119) ........G —...
Page 13 Guide to the Operating Instructions In this chapter you will find notes and information that will help you use these Operating Instructions. Do not hesitate to contact us if you have any queries: Putzmeister Concrete Pumps GmbH After Sales Department Max−Eyth−Straße 10 D−72631 Aichtal Germany Telephone +49 7127 599−0...
Page 14 Guide to the Operating Instructions BP01_001_0802EN...
Page 15 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 16 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 17 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 18 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 19 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 20 Guide to the Operating Instructions AusgleichsseiteEN...
Page 21 Safety regulations Safety regulations These safety regulations conform to the chapters Terms, definitions, requirements" and Starting up and working with the machine" in the German Engineering Federation (VDMA) brochure Safety manual Concrete delivery and placing machines". Here you will find a summary of the most important safety regula tions.
Page 22 Safety regulations BP03_081_1701EN...
Page 23 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 For the purposes of this Safety Manual, concrete delivery and plac ing machines are defined as: −...
Page 24 Safety regulations 2.1.6 Truck mixer For the purposes of this Safety Manual, truck mixers are defined as vehicles with mixing equipment for transporting concrete. 2.1.7 Delivery line systems For the purposes of this Safety Manual, delivery line systems are defined as self−contained pipes or hoses in which concrete is pumped from the concrete pump to the placement site.
Page 25 Safety regulations 2.1.14 Truck mixer driver Persons who supply the concrete pump with concrete from a truck mixer. Truck mixer drivers must be instructed by the machine oper ator to operate the operating elements on the concrete pump pro vided for their use. Truck mixer drivers must be able to indepen dently evaluate all dangerous situations which may occur when working in the area of the hopper of a concrete pump and react ac cording to the situation.
Page 26 Safety regulations 2.1.19 Place of work, working area, danger zone Mobile machines ab0005 Example Stationary machines ab0010 Example BP03_082_1901EN...
Page 27 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 machine operators of the manual placing system...
Page 28 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 The machine operator’s place of work is with the remote control chine operator when the pump is in operation.
Page 29 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 30 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 31 Safety regulations Designated use The machine must only be operated as intended and in technically perfect condition. All protective and safety oriented devices, par ticularly removable protective devices and EMERGENCY STOP de vices, must be available and fully functional. The machine is designed exclusively for the delivery and placing of concrete up to a bulk density of 2400 kg/m .
Page 32 Safety regulations 2.2.1 Retesting (safety in- After initial commissioning of the machine, the operational safety of spection) the machine must be checked regularly by a subject expert. The inspection intervals depend on the age of the machine. The older the machine, the greater the probability of damage. For this reason, regular retesting of the machine, appropriate to its age, must be carried out in order to detect damage in good time.
Page 33 Safety regulations 2.2.2 Inspection intervals The inspection intervals are fixed as follows: for retesting Machines up to and including 5 years old: Inspect after every 1000 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 34 Safety regulations Improper use Any use of the machine which is not described in section 2.2, en 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 35 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 36 Safety regulations 2.3.7 Impermissible work- During pumping operations, the end hose must not be moved ing area backwards beyond the vertical axis of rotation of the placing boom. wz0026 In addition to this, additional impermissible working areas exist, de pending on the machine model and manufacturer, which are de scribed in the Operating Instructions.
Page 37 Safety regulations 2.3.9 High-pressure deliv- It is prohibited to deliver concrete at high pressure (delivery pres sure greater than 85bar) through the delivery line of the placing boom. Delivery line elements are marked with the maximum per missible delivery pressure. The delivery line and end hose are only suitable for delivery pressures of up to 85bar until the wear thresh old is reached.
Page 38 Safety regulations 2.5.1 Requirements Persons operating or carrying out maintenance work on the ma chine must meet the following requirements: − They must be aged 18 years or over. − They must be physically and mentally capable. − They must be physiologically capable (rested and not under the influence of alcohol, drugs or medication).
Page 39 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, particularly the "Safety Regula tions" section, and the Safety Manual before working with the ma chine.
Page 40 Safety regulations 2.6.2 Operating procedures The operator must produce operating procedures for their person nel in accordance with national regulations. These operating pro cedures must include instructions covering the duties involved in supervising and notifying special organisational features, e.g. or ganization of work, working procedures or the personnel entrusted with the work.
Page 41 Safety regulations Personal protective In order to reduce risks to personnel, personal protective equip equipment ment must be used in so far as this is necessary or deemed to be so by regulations. All personnel working on or with the machine must wear safety helmets, protective gloves and safety footwear.
Page 42 Safety regulations Protective gloves Protective gloves protect your hands against aggressive or chemical substances, as well as against mechanical effects (e.g. impact) and cutting injuries. (DIN EN 388; Protective gloves against mechanical risks; Class 1111) Protective goggles Protective goggles protect your eyes against injuries from concrete spatters or other particles.
Page 43 Safety regulations Before working with the machine 2.8.1 Checking that the ma- As machine operator, it is your responsibility to check the machine chine is ready for for external damage and defects before any use of the machine. operation You must immediately report any changes (including changes in the working characteristics) to the organization or person responsible.
Page 44 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 45 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 46 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 minimum clearances to high voltage lines that are smaller than the required minimum clearances to be used. Previous experience has shown that high voltage warning devices cannot make all situations in working procedures safe.
Page 47 Safety regulations Electricity generator works are always equipped with automatic start up systems. If a circuit breaker trips, the short−circuited line will be switched back on again after a brief interval. Brief intervals where the voltage is absent create a false sense of safety. You must not move or rescue injured persons until a representative of the power station has notified you that the line has been switched off.
Page 48 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. 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 49 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 50 Safety regulations 2.11 Mobile machines 2.11.1 Set-up site Site management must prepare and assign the set−up site. It is the machine operator who takes responsibility for setting up the ma chine safely. The machine operator must inspect the set up site pro posed by site management and must refuse to set the machine up at the site of operations if there are any doubts regarding safety.
Page 51 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 pres sure. If the load−bearing capacity is unknown, assume the that worst case scenario applies. wz0087 The supporting ground must be level and even.
Page 52 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 clear ance must be determined in accordance with the nature of the ground.
Page 53 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 54 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 55 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 secured.
Page 56 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 57 Safety regulations 2.11.7 Loading Many lifting points fitted to the machine are provided for assembly purposes only. They are not suitable for lifting the complete ma chine. The lifting points for lifting the entire machine are specially marked. wz0176 Use only appropriate means of transport and lifting equipment of adequate load−bearing capacity.
Page 58 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 59 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 60 Safety regulations 2.12.2 End hose The end hose must hang freely each time you start pumping, when you start pumping again after blockages, and during washing out procedures. No one should stand within the danger zone of the end hose. The diameter of the danger zone is twice the end hose length.
Page 61 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 submerged below the surface of the concrete being delivered, otherwise the concrete may spray upwards. The concrete may also spray from the end hose due to the pres ence of air in the delivery line.
Page 62 Safety regulations 2.12.5 Procedure in storms Return the placing boom to the driving position or rest position in the event of storms or bad weather. − Placing booms with a vertical reach of 42 m or more may only be operated in winds of up to wind force 7 (wind speed 51 km/h).
Page 63 Safety regulations 2.13 Delivery line systems 2.13.1 Suitable delivery lines Only use delivery lines, end hoses, couplings, etc. which are in per fect condition and suitable for the delivery job and have been ap proved by the machine manufacturer. Delivery lines are subject to wear which varies according to the delivery pressure, concrete composition, the material from which the delivery line is made, etc.
Page 64 Safety regulations 2.13.3 Leak tightness and Regularly force water through the delivery line under operating blockages pressure to check that the system is watertight. wz0047 A properly cleaned delivery line is the best insurance against the formation of blockages. Blockages increase the risk of accidents. Never attempt to push through a blockage (e.g.
Page 65 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 deliv ery line is opened. Never work bending directly over the coupling. wz0076 2.13.5 Clearance to delivery No one should remain in the vicinity of separate delivery lines dur...
Page 66 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 placing boom control system to prevent unintended movements of the placing boom.
Page 67 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 remote control, all operating and control devices on the ma chine must be closed to prevent unauthorized access.
Page 68 Safety regulations 2.14.4 Moving machine com- Keep all access covers, maintenance flaps, guards, etc. closed ponents and hot sur- and locked during operation. This also applies in particular to the faces grille, water box cover and covers over cylinders. There is other wise a risk of injury from moving machine components and a risk of burning on hot surfaces.
Page 69 Safety regulations 2.14.5 Constant observation You should be constantly observing the machine for any damage or of the machine faults while it is in use. In the event of faults or malfunctions that im pair safety at work, shut the machine down immediately and secure it.
Page 70 Safety regulations 2.15 Cleaning 2.15.1 General You must drain the delivery line, pump and hopper completely. Concrete leavings in the hopper, in particular, may be thrown out whilst the truck is moving. The machine must not be driven with the placing boom unfolded or the support legs extended, even over short distances.
Page 71 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 72 Safety regulations 2.15.3 Cleaning with com- When the delivery line is being cleaned with compressed air, there pressed air is an increased risk of accidents caused by compressed air escap ing explosively, spurting concrete, and delivery or end hoses mov ing uncontrollably if they have not been removed.
Page 73 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 during the cleaning process. The pressure in the delivery line must be rapidly dumped via the dump cock in the event of a sudden drop in pressure (concrete column exiting from the end of the line) or increase in pressure (risk of blockage).
Page 74 Safety regulations AusgleichsseiteEN...
Page 75 General technical description 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 76 General technical description BP02_001_0302EN...
Page 77 General technical description Overview Below you will find an overview of the components that are de scribed on the following pages. Left-hand side AP02_967_1509EN 1 Component Page Documentation accompanying the machine − Engine (see manufacturer’s documentation) − System for exhaust gas treatment Hydraulic pumps −...
Page 78 General technical description Right-hand side AP02_967_1509EN 2 Component Page Central module control cabinet Hydraulic indicators Remote control Machine rating plate DEF container (see manufacturer’s documentation) − Magnetic switch distributor casing Buzzer − Control block − Delivery cylinder emergency control lever Transfer tube change−over valve Connection for remote control −...
Page 79 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 80 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 81 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 1409 D Height 2510...
Page 82 General technical description 3.3.1 Electromagnetic The machine in question meets the requirements set out in Appendix compatibility (EMC) 1 of Directive 2014/30/EU of the European Parliament and of the Council of 26 February 2014. The electromagnetic compatibility has been tested and meets the requirements set out under EN 13309:2010−12.
Page 83 General technical description 3.3.2 Machine rating plate The following rating plate is attached to the machine: Betonpumpe BSA 1409 D4 210110932 BP22_830_1005EN 1 Designation Designation of the machine Machine model Machine number Maximum fluid pressure in the hydraulic system [bar]...
Page 84 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 85 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 86 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 87 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 88 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 89 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 90 General technical description 3.4.5 Transfer tube damping The transfer tube is switched more slowly when transfer tube damping is switched on (lever on the snail symbol), this protects the switching mechanism for the transfer tube. Transfer tube damping can however only be used if the concrete is very fluid and must only be pumped at low concrete pressure.
Page 91 General technical description 3.4.6 Agitator The hopper is equipped with a hydraulically driven agitator. The agitator performs two functions: − it improves the filling rate of the delivery cylinders; − it mixes the concrete. AP02_055_9710EN 1 Designation Hydraulic motor Agitator shaft Agitator helix Improving the The filling rate in the delivery cylinders should be as high as possible...
Page 92 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 93 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 94 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 95 General technical description 3.5.5 Centralized The centralized lubrication system comprises a lubricant pump / lubrication system grease gun, lubricant distributors, relief valves and supply lines. AP02_789_1009EN 1 Designation Lubricant reservoir Lubricant pump Grease gun Lubricant distributor Agitator shaft bearings Transfer tube bearing Supply lines from the dry running cut out lubricant distributor Upper switch cylinder bearings Lower switch cylinder bearings...
Page 96 General technical description The centralized lubrication system supplies the connected lubrica tion points with grease and hydraulic fluid. The lubrication points are lubricated in fixed cycles. Lubricant reservoir The lubricant reservoir may be filled up to the Max" marking through the filling nipple or from above through the filling opening.
Page 97 General technical description 3.5.6 Dry running cut-out The dry running cut out comprises a lubricant distributor and the lines to the lubrication points. The lubricant distributor inlets are connected to the hydraulic circuit of the switch cylinders. Lubricant distributor Á Á AP02_789_1009EN 2 Designation Inlet...
Page 98 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 99 General technical description 3.6.1 Central module con- On the central module control cabinet, you can control the functions trol cabinet of the pumps and the systems for exhaust gas treatment and detect the operating states of the machine and the exhaust after treatment system.
Page 100 General technical description Right–hand view AP02_969_1508EN 2 Operating/ Pos. Meaning/function Comments control element Power socket, 1 pin Connection for working light optional Round socket, 4 pin Connection for vibrator optional Locally latched toggle Local control − 0 − Remote control switch Bush Connection for remote control...
Page 101: Remote Control
General technical description Special features of the control cabinet Closing and locking the The control cabinet is located in a stowage compartment. You must control cabinet keep this stowage compartment locked at all times to prevent un authorized persons from switching the control system over. Caution Depending on the design, the stowage compartment cannot be closed on some machines when the cable remote control is used.
Page 102 General technical description Note Abbreviations used: EAT = Exhaust After Treatment (exhaust gas treatment) DEF = Diesel Exhaust Fluid (urea solution used in exhaust gas treat ment, e.g. AdBlue") *DPF = Diesel Particle Filter *DOC = Diesel Oxidation Catalyst *SCR = Selective Catalytic Reduction * = Machine−specific Note When the Regeneration"...
Page 103 General technical description Manually switching on Switch on the regeneration procedure on the central module control the regeneration pro cabinet as follows: cedure − Switching the toggle switch from Pumping operation" to Enable regeneration" interrupts the pumping operations and enables the regeneration procedure.
Page 104 General technical description Manually switching off Switch off the regeneration procedure on the central module control the regeneration pro cabinet as follows: cedure − Pressing the toggle switch Regeneration On − Off" again inter rupts the regeneration procedure or stops the procedure. −...
Page 105 General technical description 3.6.2 Ergonic Graphic The Ergonic Graphic Display (EGD) is a graphic display and Display control unit on the control cabinet. The EGD allows you to determine the operating state of the machine. You can use the EGD operating elements to navigate in the menu structure and to make settings.
Page 106 General technical description EGD and operating elements BP22_949_1104EN 1 Operating/ Function / meaning control element Ergonic Graphic Display Menu driven displays and adjustable functions are (EGD) shown in the EGD. Push button HOME" function key Push button Help" function key Function button F4 for selecting or setting symbols and Rotary/push button numerical values.
Page 107 General technical description Using the menus The HOME" function key takes you back to the HOME" menu from any of the sub menus. The Help" function key displays a help screen for each menu. You can navigate in the menu structure using function buttons F1, F2, F3 and F4.
Page 108 General technical description Menu structure The following pages show the password−free section of the menu structure (example). When the machine is set up, HOME" is dis played as the start screen for 5 seconds. AP02_970_1410EN 1 AP02_970_1410EN...
Page 109 General technical description Display Function/meaning page Displayed for 5 seconds once the ignition is Test screen switched on. HOME Data display Press HOME" in HOME to display the Info" Info menu. Press Help" in HOME to display the menu Help structure.
Page 110 General technical description Test screen This test screen is displayed for 5 seconds as soon as the ignition is switched on. BP22_944_1104EN 1 Display Function / meaning Version The software version number Test screen Screen displayed when switched on BP22_944_1104EN...
Page 111 General technical description “HOME” menu HOME" is displayed after the machine is set up.In this menu, the function buttons have the following functions: − F1 = Pump status" menu − F2 = Pump settings" menu − F3 = Pump flow meter" menu −...
Page 112 General technical description AP02_971_1501EN 2 Continued Pos. Display Function/meaning Operating hours meter The machine operating hours are displayed. Stroke counter The total strokes for the machine are displayed. The current concrete pressure is displayed in Concrete pressure, digital numbers. The current concrete pressure is displayed graphically. Concrete pressure, ana The scale for the graphic display ranges from 0 to the logue...
Page 113 General technical description AP02_971_1501EN 3 Continued Pos. Display Function/meaning Navigation symbol and Press F4 to display the Service" menu. Service" menu Navigation symbol Press F3 to display the Pump flow meter" menu. The Local control 0 remote control" switch setting Navigation symbol and se is displayed.
Page 114 General technical description Special features of the displays in the “HOME” menu Concrete pressure The concrete pressure value is calculated from the hydraulic pump display high pressure. When the concrete pump is switched off, the value 8888" is displayed. Danger Even though the concrete pump is switched off, there may be a high concrete pressure in the delivery line (e.g.
Page 115 General technical description Symbols for the “HOME” menu Note Depending on the equipment fitted to your machine, some of the functions illustrated may not be present. The symbol is not lit if a function is not present. Warning Symbol lights up yellow if a limit has been reached, for example. Agitator safety cutout Symbol lights up red if the agitator safety cutout has been activated.
Page 116 General technical description Fill level warning symbol for the DEF container (green) Symbol lights up dark green if the fill level in the DEF container is >15%, and light green if the container content is between <15% and >10%. Fill level warning symbol for the DEF container (yellow) This symbol lights up yellow if the container content is between <...
Page 117 General technical description “Pump status” menu In this menu, you can see the various operating states. In this menu, the function buttons have the following functions: − F1, F2, F3 = No function − F4 = Switch sensors on or off AP02_973_1508EN 1 Pos.
Page 118 General technical description AP02_973_1508EN 2 Continued Pos. Display Function/meaning High pressure The high pressure of the hydraulic fluid is displayed. Number of strokes The number of strokes per minute is displayed. Stroke time The current stroke time is displayed. Engine speed The current engine speed is displayed.
Page 119 General technical description Symbols for the “Pump status” menu Note Depending on the equipment fitted to your machine, some of the functions illustrated may not be present. The symbol is not lit if a function is not present. Engine speed Symbol flashes if there is no speed of rotation signal (e.g.
Page 120 General technical description Hydraulic fluid overheating This symbol flashes if the temperature sensor in the leakage oil line of the main hydraulic pump measures at least 85 °C or is defective. Then the delivery rate is gradually reduced to 20%, and the Warn ing"...
Page 121 General technical description High pressure Symbol flashes if the pressure sensor on the main hydraulic pump is defective. You can switch off the sensor (see page 3 46). This automatically limits the delivery rate to 50 %. The pump settings are automatically set to the factory values.
Page 122 General technical description Overriding sensors If a sensor signal that transmits data relevant to the pump control system fails, sensors can be overridden if you switch off the sensor. The following displays are possible: Sensor ... working defective switched off Symbol normal flashing...
Page 123 General technical description “Pump settings” menu In this menu, you can set the machine’s performance data and oper ate some of the machine’s functions from the control cabinet. In this menu, the function buttons have the following functions: − F1 = select from between engine speed (rpm), delivery rate or stroke count −...
Page 124 The factory settings of the EOC can be modified at any time by a tings Putzmeister service technician. As soon as current is no longer supplied to the control cabinet (e.g. ignition off), the settings are reset to the factory settings.
Page 125 General technical description 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. AP02_977_1411EN 1 Display Function/meaning Concrete pressure limit, The set concrete pressure limit is shown graphically, analogue and can be adjusted using the rotary push−button F4.
Page 126 General technical description AP02_977_1411EN 2 Continued Display Function/meaning The date and time appear, and can be adjusted using Date / time the rotary push−button F4. Symbol lights up red if the agitator safety cutout has Agitator safety cutout been activated. The symbol lights up red if an EMERGENCY STOP but EMERGENCY STOP ton has been operated.
Page 127 General technical description Symbols for the “Pump settings” menu Note Depending on the equipment fitted to your machine, some of the functions illustrated may not be present. The symbol is not lit if a function is not present. If a function can be switched to External" (symbol plus arrow), then the function can be switched on/off by radio remote control.
Page 128 General technical description Centralized lubrication system The symbol lights up green during the lubrication procedure. You can start a manual lubrication procedure by using the F4 func tion button to select and press the symbol. The symbol lights up red if there is a fault on the centralized lubrica tion system or a lubricant reservoir is empty.
Page 129 General technical description EOC (Ergonic Output Control), (optional) The function can be switched on/off (I/0) or switched to External" using the function buttons. Stroke counter The current number of strokes is shown next to the symbol. You can reset the stroke counter to 0" by selecting the symbol with the F4 function button and pressing it.
Page 130 General technical description SBU (switching between rod side and piston side feed) (op- tional) The pump control system must be set using the function buttons in such a way that it matches with the type of drive for the delivery cyl inder.
Page 131 General technical description Switching between On some construction sites, it is necessary to pump as much con rod side and piston crete as possible in a short time (rod side feed). On other construc side feed tion sites, on the other hand, it is necessary to pump the concrete as far or as high as possible (piston side feed).
Page 132 General technical description Switching over the The pump control system must be set using the function buttons in pump control system such a way that it matches with the type of drive for the delivery cyl inder. AP02_980_1411EN 2 SBU software switch (SBU = switching between rod side and piston side feed) Using the rotary push−button F4, you can make use of the SBU soft ware switch to switch the type of drive for the pump control system...
Page 133 General technical description Centralized lubrication system Note The pump centralized lubrication system and the boom centralized lubrication system are two completely independent systems, that is two pumps, two lubricant reservoirs, two controllers, etc. Technical data Rated voltage (V DC) 12 / 24 Operating voltage (V DC) 9 to 30...
Page 134 General technical description Programming Various settings are programmed into the centralized lubrication system in the works. These settings regulate the lubrication intervals and the lubrication time. Have the default settings modified by the After Sales Department if either the lubrication intervals or the lu brication times do not meet your needs.
Page 135 General technical description “Pump flow meter” In this menu, you can read off delivery rates in order to record job menu volumes on the construction site, service intervals or the total deliv ery rate, for instance. In this menu, the function buttons have the fol lowing functions: −...
Page 136 General technical description AP02_981_1411EN 2 Continued Display Function/meaning Pump outputs for 2 individual periods are shown. Pump output display (the values can be reset). The total pump output is displayed. Pump output display, total (the value cannot be reset). Switch The pump flow meter can be switched on/off (I/0).
Page 137 General technical description Method of operation of the pump flow meter Output The output is calculated from the geometric data of the delivery cylinders at the fill level specified by you. Switching the pump You can switch the pump flow meter on/off. When the pump flow flow meter on/off meter is switched on, the concrete pump stops as soon as the specified output is achieved.
Page 138 General technical description Setpoint value for the You can specify a value for the output at which the concrete pump output should switch off. The accuracy of the volumes indicated is depen dent on the current fill level of the delivery cylinders. The more accurately you enter the fill level in percent, the more accurate the display.
Page 139 General technical description Resetting the output Reset the Output displays 1 and 2" to zero as follows. display Turn F4 to select the arrow next to the value. " å The arrow is displayed in inverse video. Then press F4 to activate the value. "...
Page 140 General technical description Entering the fill level of Enter the fill level of the delivery cylinders as described below: the delivery cylinders Note The usual fill level of the delivery cylinders is between 70 % and 90 % (average value: 85 %). Use the formula to calculate the fill level for your own concrete mix formula: Amount of concrete in the truck mixer...
Page 141 General technical description “Engine diagnosis” In this menu, you can see the various operating states. In this menu, menu the function buttons have the following functions: − F1, F2, F3, F4 = no function Note The bar charts and fault messages are only active for engines with an electronic engine governor (EMR).
Page 142 General technical description AP02_982_1501EN 2 Continued Pos. Display Function/meaning DEF container fill level, ana The fill level of the DEF container is shown graphically. logue Cooling water temperature, The cooling water temperature is displayed in digital numbers. Cooling water temperature, The cooling water temperature is displayed graphi analogue cally.
Page 143 General technical description Special features of the “Engine diagnosis” menu EMR fault messages If there are faults in the electronic engine governor (EMR), the fault messages are shown using a numerical code in the display. You can use the numerical code to identify the fault in the system description of the electronic engine governor.
Page 144 General technical description Symbols for the “Engine diagnosis” menu Caution Be aware that engine damage can be caused if you operate a diesel engine with hidden faults in the engine governor. In emergency operation, you can recover and evacuate the ma chine, but you cannot prevent engine damage.
Page 145 General technical description Fuel filter (optional) Symbol lights up red if a fault occurs in the fuel filter or the fuel filter is dirty. Coolant level (optional) Symbol lights up red if a fault occurs in the coolant reservoir or the engine coolant level is too low.
Page 146 General technical description “Fault memory” menu In this menu, the fault codes for the last 10 faults are displayed. In this menu, the function buttons have no functions. BP22_965_1105EN 1 Display Function / meaning Fault The fault code is displayed. Date The date of the fault events are displayed.
Page 147 Control system parameters can be set in the service area of the EGD. If parameters are incorrectly set, the control system may mal function. Access to the service area is therefore password protected and only granted to Putzmeister service engineers. BP22_947_1104EN...
Page 148 General technical description “Info” menu This menu lists the software versions of the control systems. In this menu, the function buttons have no functions. BP22_946_1104EN 1 Display Function / meaning The software versions of the control systems are Software versions displayed.
Page 149 General technical description 3.6.3 Ergonic Output Ergonic Output Control (EOC) is electronically controlled delivery Control rate regulation which adapts the engine speed to the delivery rate selected. You can switch the EOC function on or off at the Ergonic Graphic Display (EGD). It is recommended that you switch off EOC in arduous pumping conditions (e.g.
Page 150 General technical description Special features of Ergonic Output Control Ergonic Output Control In the Pump settings menu you can switch the EOC control system on or off, or assign this function to the radio remote control. Note You can only switch EOC on or off at the radio remote control if you set the EOC to the radio remote control"...
Page 151 General technical description Pump On As soon as you switch on the concrete pump, the engine speed is increased to a level appropriate for the delivery rate set on the out put regulation rotary controller, but to no less than 1600 rpm. Delivery rate Engine speed 850 rpm (after 5 seconds)
Page 152 General technical description Pump Off The engine speed is reduced to idling speed after 5 seconds (works setting), when you − reduce the delivery rate to 0 %. − switch off the concrete pump. Should you switch the concrete pump back on inside this 5 second delay, the engine speed is maintained.
Page 153 General technical description Menu–independent If a serious change to the operating status of the machine occurs warnings that may lead to a major fault, this warning will appear on the screen regardless of the current system menu. Danger of fire Risk of fire due to inadequate clearance from a stationary concrete pump during the DPF regeneration procedure.
Page 154 General technical description Warning triangle, yellow Symbol lights up yellow in the following cases: − Once the tank content is between < 10% and > 5%, − If a DPF regeneration is required or if regeneration is running − If DEF quality and exhaust gas treatment are poor. Warning triangle, orange Symbol lights up orange in the following cases: −...
Page 155 General technical description Warning symbol: DPF regeneration (yellow) Symbol lights up yellow if DPF regeneration is required. Warning symbol: DPF regeneration (orange) Symbol lights up orange if DPF regeneration is required and shows the escalation stage 1. Power reduction stage 1 is activated. Warning symbol: DPF regeneration (red) Symbol lights up red if DPF filter maintenance is required and indi cates escalation stage 2.
Page 156 General technical description AP02_975_1704EN 1 Example warning illustration: DPF regeneration required Pos. Display Function/meaning Warning levels (yellow, orange and red) depend on the status of regeneration/stationary regeneration Warning triangle If the warning level is orange or red, the power to the engine is reduced Warning levels (green, yellow, orange and red) de Warning symbol...
Page 157 General technical description Fill level warning symbol for the DEF container (green) Symbol lights up dark green if the fill level in the DEF container is >15%, and light green if the container content is between <15% and >10%. Fill level warning symbol for the DEF container (yellow) This symbol lights up yellow if the container content is between <...
Page 158 General technical description AP02_975_1704EN 2 Example warning illustration: DEF fill level low, top up DEF Pos. Display Function/meaning Warning levels (yellow, orange and red) depend on the liquid level of the DEF container Warning triangle If the warning level is orange or red, the power to the engine is reduced Warning levels (dark green, light green, yellow, orange Warning symbol...
Page 159 General technical description Caution Damage to the SCR system if the diesel exhaust fluid (DEF) quality does not comply with the specifications of ISO 22241. If the DEF quality deteriorates, the complete engine system cannot comply with the permitted exhaust gas values. Do not dilute the DEF, as this will cause damage to the SCR system.
Page 160 General technical description AP02_975_1704EN 3 Example warning illustration: DEF quality inadequate Pos. Display Function/meaning Warning levels (yellow, orange and red) depend on the DEF quality and exhaust gas treatment. Warning triangle If the warning level is orange or red, the power to the engine is reduced Warning levels depending on the DEF quality and ex Warning symbol...
Page 161 General technical description Warning symbol for engine oil change required (yellow) Symbol lights up yellow if the engine oil needs to be changed. Note The engine oil must be changed every 500 hours or after the DPF has been regenerated several times, and if the warning symbol En gine oil change required"...
Page 162 General technical description AP02_975_1704EN 5 Example warning illustration: Fill level of the DEF container Pos. Display Function/meaning Warning levels (dark green, light green, yellow, orange Warning symbol and red), depending on the liquid level of the DEF container The fill level of the DEF container is shown in numbers Display, digital as a percentage.
Page 163 General technical description 3.6.4 Cable remote control The most important control functions for the pump are gathered to gether on the remote control unit, so that you can control the oper ation of the pump from here. AP02_625_1301EN 1 Operating/ Meaning/Function Comments control element...
Page 164 General technical description Special features of the cable remote control Starting up the pump If you have pressed the EMERGENCY STOP button, the EMERG after EMERGENCY ENCY STOP activated" symbol flashes on the Ergonic Graphic Dis STOP play. You may only start the pump up again as described below: −...
Page 165 General technical description 3.6.5 Operating panel You can switch functions on and off using the operating elements in the operating panel. Some of the control and operating elements illustrated below may not be present on your machine. The hole will be filled with a blank ing plug if a control or operating element is omitted.
Page 166 General technical description Special features of the operating panel Starting up the pump If you have pressed the EMERGENCY STOP button, you may only after EMERGENCY start the pump up again as described below: STOP − Unlock the EMERGENCY STOP button by turning it. −...
Page 167 General technical description 3.6.6 EMERGENCY STOP EMERGENCY STOP buttons are fitted to the following machine com button ponents: − the cable remote control − on the right−hand side of the machine in the operating panel. Caution Familiarize yourself with the positions of the EMERGENCY STOP but tons on your machine.
Page 168 General technical description The following actions are triggered when you press one of the EMERGENCY STOP buttons: − The EMERGENCY STOP symbol is shown in red on the control cabinet, − The variable main pump swings back, and the delivery pistons stop, −...
Page 169 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 170 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 LEDs on the evaluation device indicate the following: The green LED flashes for 8 seconds during the initialization process.
Page 171 General technical description 3.6.8 Magnetic switches The distributor casing for the magnetic switches is located beneath distributor casing the control cabinet. AP02_614_0706EN 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 Yellow LED Magnetic switch (piston side), drive cylinder II...
Page 172 Distributor casing status lights up continuously The distributor casing is ready for operation. does not light up The Putzmeister operating system is not supplied with a voltage. Note Additional LEDs are located on the magnetic switch connector (see page 3 97).
Page 173 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 174 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 175 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 176 General technical description 3.7.1 Water pump lever The water pump lever is used to switch the water pump on or off. AP02_245_1402EN 1 Designation Water pump off Water pump on AP02_245_1402EN...
Page 177 General technical description 3.7.2 Pump control system The hydraulic control valves are built into the pump control system. The concrete pump can be operated manually at the pump control system if a machine malfunction occurs (see service instructions, chapter Special operating modes"). Danger There is an increased risk of accident during special operation.
Page 178 General technical description 3.7.3 Agitator emergency If the control panel has failed, you can use different directions of operation rotation to manually operate the agitator from the hydraulic control block illustrated below. AP21_054_1609EN 1 Pos. Designation Agitator emergency operation AP21_054_1609EN...
Page 179 General technical description 3.7.4 Pressure gauge The hydraulic pressure of the hydraulic pump is shown on the pressure gauge. AP02_063_0308EN 1 3.7.5 Filter condition The condition of the suction filter can be seen on the vacuum meter, that of the pressure filter can be seen directly on the filter housing. Suction filter AP02_063_0308EN 2 Vacuum meter...
Page 180 General technical description 3.7.6 Automatic–Piston– The APP system makes it easier to fit and remove the delivery pis Pull (APP) tons. A ball valve is fitted in the stroke correction line of each drive cylin der. The two ball valves are open and secured by guide washers. The ball valves may only be closed when the delivery pistons are being replaced.
Page 181 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 182 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 can be switched on and off manually on the control cabinet. 20204201 Description Control cabinet symbol for the hydraulic fluid radiator...
Page 183 General technical description 3.8.2 Flushing water pump Depending on the machine specification, it may be equipped with either a Hypro WP 50 or a CRK 4−160. Flushing water pump The flushing water pump Hypro WP 50 generates a water pressure of Hypro WP 50 20 bar at a water delivery rate of 50 litres per minute maximum.
Page 184 General technical description Flushing water pump The flushing water pump CRK 4−160 generates a maximum water CRK 4–160 pressure of 25 bar and a maximum water delivery rate of 160 litres per minute. AP02_787_1008EN 1 Designation Water pressure gauge Connector for water hose Flushing water pump Hydraulic ports Hydraulic motor...
Page 185 General technical description 3.8.3 Vibrator The vibrator is bolted to the grille. It causes the grille to vibrate and thus prevents bridges forming on the grille, particularly in the case of very stiff concrete. The vibrator is electrically driven; the connecting plug must be plugged into the appropriate socket on the control cabinet for this to work.
Page 186 General technical description 3.8.4 Exhaust after treat- This section provides a description of the exhaust after treatment ment system system. The engine and its exhaust after treatment system are coordinated with one another and form a complete engine system. The complete engine system meets the permitted exhaust gas emission levels and is certified accordingly by the relevant authorities.
Page 187 General technical description Note Refer to the engine manufacturer’s documentation for details about how the exhaust after treatment system works. Abbreviations used: EAT = Exhaust After Treatment (after treatment of exhaust gas) DEF = Diesel Exhaust Fluid (urea solution used in exhaust gas treat ment, e.g.
Page 188 General technical description Selective Catalytic Reduction (SCR) AP02_987_1702EN 1 Example illustration: SCR system Pos. Component Engine control unit Solenoid−operated valve Line heated with coolant (to preheat the DEF container) DEF container DEF delivery pump DEF line Line cooled with coolant (to cool the metering unit) SCR catalytic converter Metering unit Exhaust gas temperature sensor...
Page 189 General technical description The SCR system continuously reduces the NOx emissions produced by the engine as described below: The DEF delivery pump supplies the diesel exhaust fluid (DEF) that is injected into the exhaust system by the metering unit upstream of the SCR catalytic converter.
Page 190 General technical description Diesel Oxidisation Catalyst/Diesel Particle Filter (DOC/DPF module) AP02_987_1702EN 2 Example illustration: Diesel particle filter (DPF) Pos. Component diesel oxidisation catalyst Exhaust gas temperature sensor Pressure differential sensor diesel particle filter AP02_987_1702EN...
Page 191 General technical description The diesel oxidisation catalyst (DOC) oxidises the carbon monoxide (CO) and unburned hydrocarbons (HC) present in the exhaust gas. Within a temperature range of 200°C to 450°C, nitrogen monoxide (NO) is converted into (NO ) through oxidation. The diesel particle filter (DPF) with passive regeneration capabilities separates the soot created during the diesel fuel combustion pro cess.
Page 192 General technical description DPF regeneration strategy Note Refer to the engine manufacturer’s documentation for details about the regeneration strategy. Danger of fire Risk of fire due to an inadequate clearance from a stationary con crete pump during the regeneration procedure. During the regeneration procedure in particular, very high exhaust gas and surface temperatures occur near a stationary concrete pump (approx.
Page 193 General technical description Regeneration strat- Description/DPF soot load Ergonic Buzzer Power reduction egy/colour code Graphic Display Normal operation Regeneration not required. None Dark green DPF soot load < 62% Passive regener- Required ation 1 = Passive regeneration takes Heat mode 1 place continuously during en place continuously during en gine operation.
Page 194 General technical description Regeneration strat- Description/DPF soot load Ergonic Buzzer Power reduction egy/colour code Graphic Display Active regener- Regeneration required. ation Operation can continue but re Warning level generation is urgently required. generation is urgently required. Active regeneration must be in itiated manually by the machine Orange operator.
Page 195 Starting up 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 196 Starting up AP13_015_0303EN...
Page 197 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 198 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 199 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 200 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 201 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 202 Starting up Test run Depending on the machine’s equipment, the following sequence of actions must be carried out for the test run: − Open the ventilation flap (as soon as the machine is warm) − Open the side flaps (as soon as the machine is warm) −...
Page 203 Starting up 4.2.1 Switching on the ma- Before switching on the machine, you must set up the machine cor chine rectly, have the control cabinet connected to the electrical power supply and must set up the cable remote control for use. You can find information on this in the chapter entitled Transport, setting up and connection".
Page 204 Starting up AP13_106_1508EN 2 Example illustration Designation Ergonic Graphic Display (EGD): Setting and displaying operating states Locally latched toggle switch: Local control − 0 − Remote control Ignition−starter switch: Engine On − Off Shift the toggle switch (2) on the control cabinet to Re "...
Page 205 Starting up Operate the Deactivate EMERGENCY STOP" toggle switch on " the cable remote control. Switch the diesel engine on using the ignition starter switch (3) " on the control cabinet or using the Diesel engine On−Off" toggle switch on the cable remote control. Switch the pump on at the cable remote control using the "...
Page 206 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 207 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 208 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 209 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 210 Starting up AP13_085_1304EN 1 Designation Transponder (in the grille) LED, green and red Acknowledge agitator safety cutout on operating panel Reading head (on the hopper − example illustration) Open the grille with the concrete pump running. " å The transponder signal is broken. å...
Page 211 Starting up 4.3.4 Acknowledging the The agitator is secured against unexpected restarts. After the agitator safety cutout agitator safety cutout has been operated, it must be acknowledged before the concrete pump can be switched back on. The agitator safety cutout is triggered in the following situations: −...
Page 212 Starting up AP13_098_1402EN 1 Pos. Designation Acknowledge agitator safety cutout in the operating panel Operate the Acknowledge agitator safety cutout" toggle switch " in the operating panel. AP13_098_1402EN...
Page 213 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 214 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 215 Starting up 4.3.6 Agitator The agitator hopper grille must always be closed when the pump is in operation. Danger Risk of injury when the agitator is operating and the transfer tube is switching. When the machine is started up after the agitator safety cutout has been actuated, the agitator safety cutout must be acknowledged before the concrete pump can be switched back on.
Page 216 Starting up 4.3.7 Gate valve There must be no pumping while the gate valve is being switched. The gate valve would no longer be able to switch over safely. AP13_100_1402EN 1 Pos. Designation Open gate valve Gate valve Off Close gate valve Switch the agitator off.
Page 217 Starting up 4.3.8 Flushing water pump Depending on the machine equipment, it may be equipped with either a Hypro" or a CRK" flushing water pump. To prevent damage, never run the flushing water pump without water. You may, however, perform a short function test lasting a few sec onds without the water being connected.
Page 218 Starting up Check the flushing water pump inlet screen and, if necessary, " clean it before operation. Switch the agitator off and switch the gate valve to neutral. " On the operating panel (4), shift the Flushing water pump − "...
Page 219 Starting up 4.3.9 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 220 Starting up 4.3.10 Switching off the ma- When you shut down the machine, you must perform the following chine tasks: Switches off the pump Switch off the pump at the control cabinet. Set the output controller to min". " Switch off all power consumers. "...
Page 221 Putzmeister will not accept warranty claims for engine damage and operating errors that result from a failure to switch off the engine ac cording to the instructions.
Page 222 Starting up AP13_107_1508EN 1 Example illustration Designation Ignition−starter switch: Engine On − Off Switch off the ignition (1). " å The control unit saves required data during the run−down time (approximately two minutes). AP13_107_1508EN...
Page 223 Starting up Possible faults If you interrupt the run−down time of the control unit, the following faults may occur: Note Because the faults listed here are not control unit malfunctions, but operating errors, the work involved in rectifying them is not covered by the warranty, as stated in the general terms and conditions of DEUTZ.
Page 224 Starting up AusgleichsseiteEN...
Page 225 Transport, setting up and connection 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 226 Transport, setting up and connection AP06_001_1007EN...
Page 227 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 228 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 229 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 230 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 231 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 232 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 233 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 234: Hand Signals For Pumping
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 235 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 236 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 237 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 238 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 239 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 240 Transport, setting up and connection Setting up The machine must be level. Pay particular attention to the section headed Requirements on the set−up site". Drive the machine to the set−up site you have inspected. " AP06_016_0110EN 1 Initial situation Use chocks to secure the machine against rolling. "...
Page 241 Transport, setting up and connection Note You must extend the support feet far enough so that the wheels will no longer be in contact with the ground when the machine is sup ported. AP06_016_0110EN 3 Supporting the rear Place timber blocks or other suitable material beneath the rear "...
Page 242 Transport, setting up and connection Note Use only suitable lifting equipment for lifting the machine. The support wheel is not suitable for lifting the machine. AP06_016_0110EN 4 Raise the machine and support at the front Raise the machine by the drawbar sufficiently that the front "...
Page 243 Transport, setting up and connection AP06_016_0110EN 5 Machine set up correctly Lower the machine. " Note Recoil from the delivery line may be transmitted to the machine under extreme operating conditions (high−pressure delivery, for example). This recoil could jeopardize the stability of the machine. The support feet can be anchored to the ground (concreting them in or lashing them down with tensioning chains, for instance) to give the machine greater stability.
Page 244 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 245 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 246 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 247 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 248 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 249 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 250 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 251 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 252 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 253 Transport, setting up and connection Rod side – piston side The hydraulic hoses on the drive cylinder must be connected for rod feed side or piston side feed, depending on the job in hand. The machine is connected up for rod side feed when it is delivered. Normal delivery The drive cylinders must be fed on the rod side to pump a large quantity of concrete in a short time.
Page 254 Transport, setting up and connection AP06_071_1411EN 1 Designation Rod side feed Piston side feed Place a container beneath the ports you are changing over to " catch the fluid. Environmental protection All operating equipment and functional fluids, e.g. oils (including bio logically degradable oils), filters and auxiliary materials must be carefully collected and disposed of separately, both from each other and from other waste.
Page 255 Transport, setting up and connection Flushing water pump Depending on the machine specification, it may be equipped with either a Hypro WP 50 or a CRK 4−160. Note The water supply can be hampered by: the water hose diameter being too small the water pressure being too low for a significant head the hoses being pinched or kinked a damaged hose or...
Page 256 Transport, setting up and connection Flushing water pump CRK 4–160 AP06_056_1008EN 2 Designation Claw coupling for high−pressure water hose Claw coupling for the water supply Note Make sure that you connect the flushing water pump with a sufficient supply of water (160 litres per minute). AP06_056_1008EN...
Page 257 Pumping operations 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 258 Pumping operations AP07_026_9710EN...
Page 259 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 260 Pumping operations 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 261: 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 262 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 263: Filling The Machine With Fuel
Pumping operations Filling the machine Your machine is driven by a diesel engine. The fuel tank is integrated with fuel into the truck superstructure, and its filler pipe is located on the left side of the machine. You can use the filler opening to refuel the ma chine when it is switched off.
Page 264: Filling The Def Container
Pumping operations Filling the DEF con- This machine is fitted with an exhaust after treatment system. Ex tainer haust gas is treated using a diesel exhaust fluid (DEF), e.g. Ad Blue". Once the warning symbol Fill level of the DEF container" lights up yellow, fill the DEF container via the filler opening (see the engine manufacturer’s documentation).
Page 265 Pumping operations Caution Danger of burning when handling diesel exhaust fluid. Diesel exhaust fluid is an ultra−pure urea solution that has a caustic effect on the skin and eyes. Use your personal protective equipment when handling diesel ex haust fluid. Avoid skin contact with diesel exhaust fluid.
Page 266 Pumping operations AP07_077_1501EN 1 Example illustration: Filling the DEF container Pos. Designation Fill level warning symbol for the DEF container (yellow) DEF container AP07_077_1501EN...
Page 267 Pumping operations AP07_077_1501EN 2 Example illustration: DEF container Pos. Designation DEF container Switch off the remote controls. " Switch the pump off. " Switch the diesel engine off. " Secure the machine against being started up unintentionally. " Unscrew the lid (2) from the filler opening of the DEF con "...
Page 268: 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 269: 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 270: Inserting The Stop Plates
Pumping operations Inserting the stop plates AP07_050_0303EN 1 Caution The stop plates must be fitted in the water box during pumping operations. AP07_050_0303EN...
Page 271: 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 272: 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 273: Monitoring
Pumping operations 6.9.1 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 274 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 275: Transfer Tube Damping
Pumping operations 6.9.2 Transfer tube damping 20203903 Hare: damping valve switch position open Snail: damping valve switch position closed The damping valve is used to control the switching speed of " the transfer tube. Note You must close the damping valve when you are pumping soft consistence concrete (snail symbol) as otherwise the transfer tube switches over too harshly.
Page 276: Blockages
Pumping operations 6.9.3 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 277: Breaks In Pumping
Pumping operations 6.9.4 Breaks in pumping You should avoid breaks in pumping as far as possible, as the con crete in the delivery line can start to set, or can become segregated due the the vibrations of the machine. Note the following points if breaks are unavoidable: −...
Page 278: Engine
Pumping operations 6.9.5 Engine Do not exceed the permissible engine speed specified in the ma chine card and on the machine rating plate. Always set the engine speed higher than the vibrating speed. Do not shut down the engine immediately after periods of heavy engine loading, but first allow it to cool down at idling speed.
Page 279 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 280: Exhaust After Treatment System
Pumping operations 6.9.7 Exhaust after treat- This section describes how to operate the exhaust after treatment ment system system. Danger Risk of burning when touching components that conduct exhaust gases. During the DPF regeneration procedure/stationary regeneration, ex tremely high exhaust gas and surface temperatures arise at the ex haust gas treatment system.
Page 281 Pumping operations Automatic DPF regen- The diesel particulate filter (DPF) with passive regeneration continu eration ously regenerates automatically (without the user having to do any thing) if the filter load has reached 100% of the nominal soot load. The continuous DPF regeneration procedure lasts approx. 40 min utes and takes place at exhaust gas temperatures of approx.
Page 282 Pumping operations Stationary regener- If the filter load has reached 100% of the nominal soot load on the ation diesel particulate filter (DPF), DPF regeneration is required. A yellow DPF regeneration" warning symbol lights up in the EGD, along with the message text DPF regeneration required". The DPF regeneration/stationary regeneration must be switched on manually.
Page 283 Pumping operations Note The engine oil becomes diluted with fuel after each stationary regen eration. For this reason, the quality of the engine oil is monitored. When the yellow Engine oil change required" warning symbol lights up in the EGD, you must carry out an engine oil change. Note As soon as the DPF regeneration"...
Page 284: Restarting
Pumping operations 6.9.8 Restarting Proceed as follows if the pump has nevertheless switched off because of overheating: Set the output controller to min". " Note Never switch the engine/motor off, as the radiator must remain in operation. Refresh the water in the water box. "...
Page 285: Cleaning
Pumping operations 6.10 Cleaning Concrete leavings that are deposited inside the delivery line or transfer tube can cause damage, will accumulate and reduce the cross section. A clean delivery line and transfer tube is therefore in dispensable if you wish to be able to start pumping without problems on the next job.
Page 286 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 287 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 288: Preparations For Cleaning
Pumping operations 6.10.1 Preparations We recommend that you carry out the preparations described below for cleaning in good time to allow you to clean the delivery line and the concrete pump directly the site use is completed. Sponge balls and other accessories 10003401 Sponge pig...
Page 289 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 290 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 291 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 292 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 293 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 294: Delivery Line
Pumping operations 6.10.2 Delivery line There are a number of options for cleaning a delivery line. Some of the factors affecting which cleaning method you use include how the concrete pump has been used and what equipment you have avail able.
Page 295 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 296 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 297 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 298 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 299 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 300 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 301: 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 302 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 303 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 304 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 305 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 306 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 307: Post Cleaning Procedure
Pumping operations 6.10.4 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 308 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 309 Pumping operations 6.11 Measures for preserv- When placing stationary concrete pumps in storage for more than ing the value of sta- four weeks, you must carry out the following measures to preserve tionary concrete their value. Carry out these measures at least every three months. If pumps placed in stor- required due to the climatic conditions to which the stored machine is exposed, you must carry out these measures at shorter intervals.
Page 310 Inter rupting this run down time will cause a fault in the control unit. Putzmeister will not accept warranty claims for engine damage and operating errors that result from a failure to switch off the engine ac cording to the instructions.
Page 311: Glossary
Glossary 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 312 Glossary BP14_001_0501EN...
Page 313: Symbols For Concrete Pumps In Accordance With German Mechanical Engineering Association Standard (Vdma 24119)
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 314 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 315 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 316 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 317 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 318 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 319: Key To The Symbols For Concrete Pumps
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 320 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 321 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 322 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 323 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 324 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 325 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 326 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 327: Abbreviations And Technical Terms
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 328 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 329 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 330 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 331 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 332 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 333 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 334 Glossary BP14_002_0501EN...
Page 335: Index Of Key Words
Index of key words 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 336 Index of key words 8 — II...
Page 337 Index of key words F 8, Hydraulic, 3 99 F 25, Hydraulic fluid radiator, 3 106 Abbreviations, F 80, Magnetic switches distributor casing, G 15 3 95 Static base structure, Accessories and attachments, 2 15 Pump control system, 3 101 Transport, Accumulator, 3 101...
Page 338 Index of key words Electromagnetic compatibility, Definition of terms, Conveying, 3 54 Fastening delivery lines, 2 43 Coolant level, 3 69 Electrostatic charging, 2 25 Leak tightness and blockages, 2 42 Deactivate EMERGENCY STOP, 3 51 EMC, Opening the delivery line, 2 43 EMERGENCY STOP, 3 51...
Page 339 Index of key words Filter condition, Hydraulic system, 4 17 Responsibility of the machine operator, 2 16 Pressure filter, 3 103 Suction filter, 3 103 Magnetic switches, 3 95 Flash over, Connector with LEDs, 3 97 2 24 Icons, Function check, 4 10 Flushing water pump, 107,...
Page 340 Index of key words Sound pressure level, Procedure in storms, 2 40 Unfolding, 2 36 Space requirement, For truck mixers, Wind speeds, 2 40 Rating plate, Machine, 5 11 Preparations for cleaning, 6 30 Reaches, Extending, Starting pumping, 2 12 6 13 Preserving the value of stationary Ready for operation...
Page 341 Index of key words Warning triangle, red, Power reduc- Sound pressure level, tion stage 2, 3 78 Technical terms, G 15 Warnings, Menu–independent, 3 77 Temperatures, 3 18 Wash–out adaptors, 6 32 Restrictions, 2 40 Water, Test run, 2 51 Diesel engine, Water box, Machine,...
Page 343 Translation of the original Operating Instructions Stationary concrete pump BSA 1409 D4 Machine no. 210110932 19−03−04 The paper on which this document is printed is 100% chlorine free E Putzmeister Concrete Pumps GmbH 1994...
Page 344 Carrwood Road PMUK GB−Chesterfield +44−1246−26 00 77 www.putzmeister.co.uk Derbyshire S41 9QB Türkiye +90−282−735−1000 pm@putzmeister.com.tr Putzmeister Makine Sanayi ve Tic. A. 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 pmr@putzam.com...
Page 345 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 346 BP00_030_0911EN...
Page 347 Table of contents Table of contents Guide to the Service Instructions Foreword ......... . . 1 —...
Page 348 Table of contents Safety equipment Overview of the safety equipment ....3 — 1 3.1.1 Active safety functions ....... . 3.1.2 Passive safety functions .
Page 349 Table of contents Maintenance Daily tasks ......... . 5 —...
Page 350 Table of contents Maintenance cards 00−001 Visual checks ....... 03−002 Function checks .
Page 351: Guide To The Service Instructions
Guide to the Service Instructions This chapter contains notes and information that will help you to use these Service Instructions. Do not hesitate to contact us if you have any queries: Putzmeister Concrete Pumps GmbH After Sales department Max Eyth Str. 10 72631 Aichtal...
Page 352 Guide to the Service Instructions BP01_009_1011EN...
Page 353: Foreword
Guide to the Service Instructions Foreword The Service Instructions contain important information about the maintenance of the machine. Observing these instructions helps to avoid danger, to reduce repair costs and downtimes, and to increase the reliability and service life of the machine. The Service Instructions must be supplemented by the relevant national rules and regulations for accident prevention and environ mental protection.
Page 354 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 BP01_010_1011EN...
Page 355: Icons And Symbols
Guide to the Service 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 356 Guide to the Service 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 357 Guide to the Service 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 359: Safety Regulations
Safety regulations Safety regulations These safety regulations conform to the chapter Maintenance and special work" in the VDMA brochure Safety manual Concrete delivery and placing machines". The safety regulations in the Operating Instructions must also be fol lowed for all maintenance and special work. Note Special safety regulations may be necessary for some tasks.
Page 360 Safety regulations BP03_083_1701EN...
Page 361: Basic Principle
2.1.1 Exclusion of liability We state here expressly that Putzmeister accepts no liability for dam age arising from incorrect or negligent operation, servicing or main tenance or as a result of use contrary to the designated use. This statement is particularly valid for modifications to, additions to and customization of the machine that are liable to compromise safety.
Page 362: Requirements For Special Work
Safety regulations Requirements for In the capacity of operator, it is your responsibility to provide all the special work necessary information to the personnel concerned before special work or maintenance work is carried out. Someone should be nomi nated as the person responsible for this. Carry out the maintenance and inspection operations and comply with intervals specified in the Operating Instructions, including specifications for the replacement of parts and equipment.
Page 363 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 adequate lifting capacity. Never stand under suspended loads. Attachment of loads and signalling to crane operators should only be entrusted to experienced personnel.
Page 364: Welding
Safety regulations Welding Only carry out welding, flame cutting and grinding operations on the machine once this has been expressly approved by the manu facturer. Only qualified personnel may carry out welding work in line with manufacturer specifications, especially on the placing boom, on the supports, on load−bearing parts, on fuel and oil tanks or other com ponents which are important for industrial safety.
Page 365: Working On The Placing Boom
Safety regulations 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 366: Software
Safety regulations Software If a machine is equipped with software, the software may only be used as is provided for in the manufacturer’s Operating Instructions. Only persons authorized by the manufacturer may intervene in the machine’s software. This also applies to updates. Unauthorized interventions in the machine’s software may lead to severe damage and accidents.
Page 367: Electrical Power
Safety regulations Electrical power 2.8.1 General Work on electrical systems or operating equipment must only be carried out by qualified personnel. For further information on ma chines operated on the site power supply, see also sec tion 2.8.3, entitled Power at the construction site". wz0235 Machine components which are to undergo maintenance work must be de energized.
Page 368: Electrical Components
Safety regulations 2.8.2 Electrical components Control cabinet, motor and control elements are protected as stan dard in accordance with degree of protection IP 54. IP 54 means: − Complete protection against contact with live components or in ternal moving parts. Protection against damaging dust deposits. −...
Page 369: Hydraulic Systems
Safety regulations Hydraulic systems 2.9.1 General Work on hydraulic systems must only be carried out by qualified personnel. Always wear your personal protective equipment when carrying out work on the hydraulic system. Escaping fluid is toxic and can pen etrate the skin. wz0245 Injection through the skin is a major medical emergency.
Page 370: Replacing Hydraulic Hoses
Safety regulations Lay and install hydraulic lines in accordance with the current rules of engineering. Connections must be fitted at the appropriate points. Fittings and the length and quality of the hoses must comply with requirements. You must carefully vent the hydraulic system after any maintenance work, as there is otherwise a risk of injury caused by swinging and telescopic support legs extending rapidly, the placing boom lower ing, etc.
Page 371: Exhaust Fumes
Safety regulations 2.11 Exhaust fumes Vehicle exhaust gases contain constituents which can be lethal or carcinogenic. Operate internal combustion engines and fuel−oper ated heating systems only in adequately ventilated premises. Be fore starting up the engine in enclosed spaces, make sure that there is adequate ventilation and direct the exhaust gases away from the place of work.
Page 372: 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 373 Safety equipment Safety equipment The safety equipment on the machine is described in this chapter. In particular, it contains information about − Intervals for inspection by subject experts − Intervals for function checks BP15_001_1202EN...
Page 374 Safety equipment BP15_001_1202EN...
Page 375 Safety equipment Overview of the safety Depending on the type of machine and its equipment, the following equipment safety equipment may be fitted. Please see the machine card for de tails about which safety equipment your machine has been fitted with.
Page 376 Safety equipment 3.1.4 Safety–related parts (SRPs) Danger Incorrect assembly of safety−related parts can result in malfunctions. This creates a risk of death. Safety−related parts (SRP) should only ever be repaired, maintained or replaced by qualified personnel with the necessary authorisation. Safety related parts (SRP) are components that ensure the safety of the machine functions.
Page 377 10" = 10 years Symbol: Hourglass" Service life of the SRP Example illustration: Spare parts sheet Graphic EB00−5 XXXXX−XXXX" Safety−related parts Note Putzmeister specifies a service life (3) for every safety−related part. SRPs must be replaced once this service life has elapsed. AP15_002_1701EN...
Page 378 Safety equipment 3.1.5 Safety components The following listed parts are defined as safety components. This in cludes the following components in particular: − Pressure limiting valves Danger Incorrect assembly of components can result in malfunctions. This creates a risk of death. Safety components should only ever be repaired, maintained or re placed by qualified personnel with the necessary authorisation.
Page 379 Safety equipment EMERGENCY STOP function ISO 13849 1:2015 category 1 PL c Intervals for inspection by a annually subject expert Intervals for function checks Before the machine is used each time 3.2.1 Description of the As soon as an EMERGENCY STOP button is pressed, all dangerous functions machine movements stop.
Page 380 Safety equipment 3.2.2 Function check It is only possible to intervene quickly in the event of danger if all the EMERGENCY STOP buttons are working properly. Switch the pump and agitator on. " Press one of the EMERGENCY STOP buttons. "...
Page 381 Safety equipment Agitator safety cutout ISO 13849 1:2015 category 1 PL c Intervals for inspection by a annually subject expert Intervals for function checks Before the machine is used each time Danger Risk of injury when the agitator is operating and the transfer tube is switching.
Page 382 Safety equipment 3.3.1 Description of the This machine is fitted with an agitator safety cutout (RSA). As soon functions as you open the grille, the signal between the transponder and read ing head is broken. This causes the agitator to halt and the pressure to be dumped from the accumulator (if fitted) or the change−over valve to be de−energized, i.e.
Page 383 Safety equipment 3.3.2 Function check AP15_005_1701EN 2 Open the grille with the concrete pump running. " å The transponder signal is broken. å The agitator must come to a halt immediately. å The transfer tube must no longer switch over. å...
Page 384 Safety equipment Safety action: å The agitator must come to a halt immediately. å The hydraulic fluid pressure in the accumulator (if fitted) is dumped (see the pressure gauge). å The change−over valve is de−energized (depending on the machine). å The transfer tube must no longer switch over. Technical action: å...
Page 385 Safety equipment 3.3.3 Acknowledging the The agitator is secured against unexpected restarts. When the ma agitator safety cutout chine is set up, and when the agitator safety cutout is triggered, it must be acknowledged on the operating panel before the concrete pump can be switched back on.
Page 386 Safety equipment Separating protective devices ISO 13849 1:2015 category 1 PL c Intervals for inspection by a annually subject expert Intervals for function checks Before the machine is used each time 3.4.1 Description of the A protective device is an obstacle (e.g. cover) located between the functions machine operator and the danger zone.
Page 387 Safety equipment AP15_004_1701EN 1 Example illustration Pos. Safety equipment Covers over the switch cylinders Side protection doors Exhaust guard Grille on V−belt (depending on the machine) Water box cover Spray guard Grille on the hopper AP15_004_1701EN...
Page 388 If the residual ma terial thickness is reached, you must have the grille replaced by qualified personnel authorized by Putzmeister. Once the grille has been replaced, the agitator safety cutout must be reset.
Page 389 Safety equipment 3.5.2 Function check BP15_009_1608EN 1 Measure the width (W) and height (H) of the bars in an area " with high wear, preferably in the middle of the grille. Measure the width (W) and height (H) of the bars in an area "...
Page 390 Safety equipment Plates Intervals for inspection by a annually subject expert Intervals for function checks Once a month 3.6.1 Description Plates on the machine warn operators of dangers that cannot be pre of the functions vented by means of the design. Note You will find the locations of the plates on the machine circuit dia grams, which indicate which plate should be affixed where.
Page 391 Special modes of operation Special modes of operation The machine’s special operating modes are described in this chapter. Special operating modes are, in particular: − Operation in situations of increased risk − Operation with limited functions Danger There is an increased risk of accident during special operation. Special operation must only be carried out if: You have been trained for these activities by the machine manu facturer...
Page 392 Special modes of operation AP16_001_1609EN...
Page 393 Special modes of operation Emergency operation The hydraulic control valves are built into the pump control system. – pump function They are only for emergency manual operation of the machine when the control system fails. Danger There is an increased risk of accident during special operation. Special operation must only be carried out if: You have been trained for these activities by the machine manu facturer...
Page 394 Special modes of operation AP16_005_1701EN 1 Pos. Designation Transfer tube change−over valve Delivery cylinder emergency control lever Operating the pump control system Delivery cylinder If the control system fails, you can operate the delivery cylinders emergency control using the emergency control lever. lever Press the delivery cylinder emergency control lever to the left "...
Page 395 Special modes of operation Agitator emergency If the control panel has failed, you can use different directions of operation rotation to manually operate the agitator from the hydraulic control block illustrated below. Note The water pump lever must be in the zero position so that the fluid flow is directed to the agitator control block.
Page 396 Special modes of operation Operating the agitator emergency operation device AP16_002_1609EN 1 Example illustration Pos. Designation Agitator on − agitation direction away from the delivery cyl inder Agitator on − agitation direction towards the delivery cylin To change the agitator’s direction of rotation manually, actuate "...
Page 397 Special modes of operation Recovering the ma- If a fault occurs on the machine and cannot be rectified immediately, chine after faults you must stop site use and take steps to recover the machine. The occur delivery system may become damaged if concrete sets in it. Note Recovery of the machine is a special operating mode.
Page 398 Special modes of operation 4.3.1 Recovery with on- As long as the machine’s hydraulic drive unit is working, you can re board equipment cover the machine using on board equipment. Emergency operation The pump control system is equipped with hydraulic control valves –...
Page 399 Special modes of operation Press the delivery cylinder emergency control lever to the left " or right. å The corresponding delivery cylinder starts to move. Once the accumulator is filled (see accumulator pressure " gauge), press the transfer tube change over valve. å...
Page 400 Special modes of operation AusgleichsseiteEN...
Page 401: Maintenance
Maintenance 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 402 Maintenance BP09_001_9405EN...
Page 403: Daily Tasks
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 404: Function Check
Maintenance 5.1.2 Function check You must always check all the control and monitoring functions plus the stroke times of the pump before using it. Assembly Function checks and inspections Criterion Measure stroke times compare against test reading Engine start up/engine off fully functional General All operating elements...
Page 405: When Pumping
Maintenance 5.1.3 When pumping You must monitor the operational status of your machine and lubri cate it as required. Assembly Checking Criterion General All lubrication points lubricate as required Switching shaft bearings and seal no cement−coloured oil and grease Transfer tube Bearings and seal on the pressure mixture or slurry cement may escape connection...
Page 406: Maintenance Work
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 407: Regular Maintenance Tasks
Maintenance 5.2.2 Regular maintenance Regular maintenance tasks must be carried out in addition to the tasks daily visual inspections and function checks and servicing oper ations. Caution The maintenance intervals are specified for normal wear. You will have to shorten the maintenance intervals accordingly if you are pumping very abrasive media.
Page 408 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 409: Residual Risks During Maintenance, Inspection And Repair Work
Maintenance Residual risks during maintenance, inspection and repair work 5.3.1 Personal protective See the "Safety regulations" chapter for personal protective equip equipment ment requirements. Danger Risk of serious physical injury if personal protective equipment is not worn. Always wear your personal protective equipment during maintenance, inspection and repair work.
Page 410: Residual Risks
Maintenance 5.3.4 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 411 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 412: General Tightening Torques
Maintenance General tightening Tightening torques depend on: torques − bolt grade − thread friction − bolt head bearing area The values given in the following tables are for guidance. These va lues should only be used if no other values are specified in the rel evant chapters of the Operating Instructions or in spare parts sheets.
Page 413 Maintenance 5.4.2 Flared screwed joint, Every time the joint has been undone, the union nut must be tigh reassembly tened again securely without excessive force. Flared screwed joints External [Nm] External [Nm] diameter (RAD)/ diameter (RAD)/ Type Type * RAD = pipe external diameter = tightening torque Tighten the union nut using a spanner.
Page 414: Walformplus Threaded Union
Maintenance 5.4.4 WALFORMplus Below you will find an overview of the most important components in threaded union the WALFORMplus threaded union. The next section describes what must be borne in mind during reassembly of WALFORMplus threaded unions. BP09_022_1309EN 1 Designation Threaded connection Union nut Pipe...
Page 415: Walformplus Threaded Union, Reassembly
Maintenance 5.4.5 WALFORMplus For reassembly of the WALFORMplus threaded union, proceed as threaded union, follows: reassembly Check the thread for cleanliness and damage. " Clean the thread, and if necessary, replace the parts with a " damaged thread. Each time the connection is loosened, check the gasket for "...
Page 416 Maintenance Note The tightening torques are guide values, and only apply to optimum conditions. The torques may deviate substantially because of toler ance influences, pipes fitted under tension and incorrect lubrication. Tightening torques WALFORMplus threaded unions External [Nm] External [Nm] diameter (RAD)/ diameter (RAD)/ Type...
Page 417: Functional Fluids
− mineral hydraulic fluid (HLP) or − biologically degradable hydraulic fluid based on a synthetic ester (HEES) or − non−readily flammable hydraulic fluid (HFC). (see also http://www.putzmeister.de/deu/Hydraulicfluids.htm) Please see the machine card to find out what the initial filling was in your machine. Danger Never mix hydraulic fluids of different types, i.e.
Page 418 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 419: Level Of Contaminant
We can carry out a lubricant analysis for you should you discover that the functioning of your machine is impaired with one of the lu bricants or hydraulic fluids used. Please consult Putzmeister, Depart ment APS (After Sales) and request our analysis kit (material no.257260.004).
Page 420: Lubricant Recommendation
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 421 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 422: Oils
Maintenance 5.6.1 Oils Agitator Slewing gear Transfer Rotor gearbox gearbox transmission gearbox Requirements DIN 51 517 DIN 51 517 DIN 51 517 standard Characteristics synthetic mineral mineral see spare parts Viscosity grade, sheet CLP 220 CLP 220 CLP 220 NLGI Class Material no.
Page 423: Greases
Maintenance 5.6.2 Greases Greasing Centralized Greasing the pump (manual) lubrication system tube in rotor pumps Marking in accordance K2K−30 K1K−30 with DIN 51 502 Requirements DIN 51 825 DIN 51 825 standard Characteristics mineral, lithium soap Viscosity grade, NLGI Class 2 NLGI Class 1 NLGI Class DIN 51818...
Page 424: Hydraulic Fluids
0_C to +95_C 10_C to +80_C 20_C to +60_C Particular char biodegrades quickly non−readily flammable acteristics Initial filling Material no. 490984 000171.007 279845.009 484527 239879.002 BECHEM HYDROSTAR FUCHS HYDROTHERM Manufacturer HEES 46 46 M Changeover guidelines VDMA 24569 24314 see also http://www.putzmeister.de/deu/Hydraulicfluids.htm...
Page 425 Maintenance Maintenance cards In this section you will find the maintenance cards necessary for this machine. The table of contents includes a summary of the mainten ance cards in numerical order, you will find an alphabetical summary in the Index of key words under the entry for Maintenance cards". BP09_013_1205EN...
Page 426 Maintenance BP09_013_1205EN...
Page 427 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 428 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 429 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 430 Maintenance card 03−002 Page 2 of 2 WK03_002_1109EN...
Page 431 Maintenance card 03−026 Page 1 of 8 03–026 Checking the accumulator This maintenance card describes how to check the accumulator pre charge pressure. In Germany, the maintenance intervals are pre scribed by the Industrial Health & Safety Ordinance [Betriebsicher heitsverordnung (BetrSichV)]. Please note any applicable regulations in your country of use.
Page 432 Maintenance card 03−026 Page 2 of 8 Danger of explosion Use only nitrogen to fill the accumulator. There is a danger of ex plosion if substances such as compressed air or oxygen are used. Note Check the accumulator pre charge pressure once the hydraulic fluid has warmed up to its operating temperature (of 50 _C to 70 _C).
Page 433 Maintenance card 03−026 Page 3 of 8 WK03_026_1604EN 1 Pos. Designation Accumulator Transfer tube change−over valve Delivery cylinder emergency control lever Transfer tube damping cock Accumulator dump valve Note You can observe the pointer on the pressure gauge slowly going down as you slowly release the accumulator pressure.
Page 434 Maintenance card 03−026 Page 4 of 8 Start the machine up. " Load the accumulator with hydraulic fluid until the maximum " pressure is shown on the pressure gauge. Switch off the engine. " å The accumulator pump halts. å The accumulator dump valve remains under stress, i.e. the accumulator pressure is not dumped.
Page 435 Maintenance card 03−026 Page 5 of 8 Topping up the accu- In Germany, the persons permitted to top up the accumulator, and mulator the inspection periods, are dependent on the category classified ac cording to the Industrial Health & Safety Ordinance [Betriebsicher heitsverordnung (BetrSichV)] and on the maximum permissible pres sure.
Page 436 Maintenance card 03−026 Page 6 of 8 Recurring inspection in accordance with BetrSichV Classification of the pressure equipment in accordance with article 13 in connec- tion with appendix II of 2014/68/EU, in ac- cordance with diagram 2 Category I, category II −...
Page 437 Maintenance card 03−026 Page 7 of 8 WK03_026_1604EN 2 The hydraulic system contains an accumulator. Before maintenance work on the hydraulic system, the system must be depressurized. Danger Risk of slipping/falling or suffering impact, and even severe injury, caused by hydraulic fluid escaping under high pressure. The risk exists if the hydraulic system is not depressurized before mainten ance work.
Page 438 Maintenance card 03−026 Page 8 of 8 WK03_026_1604EN...
Page 439 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 440 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 441 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 442 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 443 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 444 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 445 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 446 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 447 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 448 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 449 Maintenance card 04−012 Page 1 of 6 04–012 Changing the suction filter This maintenance card describes how to change the suction filter element element. You will find the maintenance intervals in the maintenance summary at the start of this chapter. Note There are specific risks of an accident associated with maintenance, inspection and repair work.
Page 450 Caution Filter elements freely available on the market have too low a flow rate. You must, therefore, only ever use original Putzmeister filter elements in order to prevent damage to the machine. You must never attempt to clean filter elements. These must always be replaced.
Page 451 Maintenance card 04−012 Page 3 of 6 Changing WK04_012_1109EN 1 Designation Hexagon nut Plug Drain cock WK04_012_1109EN...
Page 452 Maintenance card 04−012 Page 4 of 6 Place a container under the drain cock (4) to allow you to catch " the escaping hydraulic fluid. Unscrew the hexagon nuts (2) as far as the stop and remove " the filter element without turning it to the stop [1.]. å...
Page 453 Maintenance card 04−012 Page 5 of 6 WK04_012_1109EN 2 Designation Hexagon nut Filter element Magnetic rod Unscrew the hexagon nut (1) from the magnetic rod (3). " Turn the filter element (2) to the left and withdraw it from the "...
Page 454 Maintenance card 04−012 Page 6 of 6 Correction dimension The filter element must be adjusted to the correct length so that the filter element opens to the rear after the filter housing has been fitted. Use the length (correction dimension) given on the spare parts sheet.
Page 455 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 456 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 457 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 458 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 459 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 460 Maintenance card 04−013 Seite 6 von 6 WK04_013_1109EN...
Page 461 Maintenance card 04−019 Page 1 of 4 04–019 DEF delivery pump filter This maintenance card describes how to change the filter element of change the DEF delivery pump. Note There are specific risks of accident associated with maintenance, inspection and repair work. For this reason, read the chapter Safety regulations"...
Page 462 Maintenance card 04−019 Page 2 of 4 Caution Corrosion damage and damage to electrical and electronic compo nents within the engine compartment caused by leaking DEF lines. Regularly check that all DEF lines and line connections are correctly seated and leaktight. Seal all leakage points (see the Exhaust after treatment system"...
Page 463 Maintenance card 04−019 Page 3 of 4 DEF delivery pump WK04_019_1709EN 1 Pos. Designation DEF delivery pump Compensating device Filter element WK04_019_1709EN...
Page 464 Maintenance card 04−019 Page 4 of 4 Shut down the engine. " Allow the engine and the exhaust after treatment system to " cool down. Disconnect the cable connections of the DEF delivery " pump (1) from the electrical connection. Place a suitable container under the DEF delivery pump (1) so "...
Page 465 No further maintenance cards required. No special tools required. Note Damage to the delivery pistons must be rectified without delay. Putzmeister accepts no warranty claims for damage to the machine resulting from failure to properly observe the maintenance regula tions. Danger Secure the working area.
Page 466 Maintenance card 06−022 Page 2 of 10 You will have to start up and shut down the machine a number of times when replacing the delivery pistons. The operations necessary for this task are described below and must be carried out conscien tiously.
Page 467 Maintenance card 06−022 Page 3 of 10 Opening the water The delivery pistons are withdrawn from the delivery cylinders with the piston rod of the drive cylinder in delivery piston replacement. To make this possible, you must first remove the stop plates in the water box.
Page 468 Maintenance card 06−022 Page 4 of 10 Shut–off the stroke You must block the drive cylinders in the end position in order now to correction lines be able to withdraw the delivery pistons from the delivery cylinders. You must close both stroke correction lines to do this. APP isolating valve 20202301 The works fits the APP isolating valve in the open state...
Page 469 Maintenance card 06−022 Page 5 of 10 20202302 As−fitted position secured against rotation Rotate position Undo the bolt on the handle and remove the handle. " Lift up the guide washer and refit it rotated through 90_. " Replace the handles and close both isolating valves. "...
Page 470 Maintenance card 06−022 Page 6 of 10 Blocking the drive cyl- You must move the associated drive cylinder to its dismantling end inders in the end posi- position before you are able to remove the delivery pistons. The pro tion cedure is as follows: Press the Change−over"...
Page 471 Maintenance card 06−022 Page 7 of 10 Caution Do not use any hard objects or caustic cleaning agents to clean the delivery cylinder. These might damage the chrome coating. Replacing the seal You may now replace the worn components on the dismantled delivery piston.
Page 472 Maintenance card 06−022 Page 8 of 10 Start the machine up. " Advance the piston rod slowly and force the new delivery " piston carefully into the delivery cylinder until the piston has reached its end position. Allow the pump to run on until the other delivery piston has "...
Page 473 Maintenance card 06−022 Page 9 of 10 20202302 As−fitted position secured against rotation Rotate position Replace the guide washer so that it is blocked in position, " fit the handle and bolt it down. Fit the base with its water outlet to the water box. "...
Page 474 Maintenance card 06−022 Page 10 of 10 WK06_022_1109EN...
Page 475 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 476 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 477 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 478 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 479 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 480 Maintenance card 07−069 Page 6 of 6 WK07_069_1109EN...
Page 481 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 482 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 483 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 484 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 485 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 486 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 487 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 488 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 489 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 490 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 491 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 492 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 493 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 494 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 495 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 496 Maintenance card 07−070 Page 16 of 16 WK07_070_1109EN...
Page 497 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 498 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 499 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 500 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 501 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 502 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 503 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 504 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 505 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 506 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 507 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 508 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 509 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 510 Maintenance card 07−071 Page 14 of 14 WK07_071_1109EN...
Page 511 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 512 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 513 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 514 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 515 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 516 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 517 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 518 Maintenance card 07−072 Page 8 of 8 WK07_072_1109EN...
Page 519 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 520 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 521 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 522 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 523 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 524 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 525 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 526 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 527 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 528 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 529 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 530 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 531 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 532 Maintenance card 07−074 Page 6 of 6 WK07_074_1109EN...
Page 533 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 534 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 535 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 536 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 537 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 538 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 539 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 540 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 541 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 542 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 543 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 544 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 545 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 546 Maintenance card 07−075 Page 14 of 14 WK07_075_1109EN...
Page 547 Maintenance card 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 548 Maintenance card 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 549 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 550 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 551 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 552 If the operating pressure is higher than 130 bar, you must ask Putzmeister what the minimum wall thickness is. WK10_007_1109EN...
Page 553 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 554 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 555 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 556 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 557 Index of key words 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 558 Index of key words 6 — II...
Page 559 Index of key words Diesel Exhaust Fluid (DEF) delivery Hydraulic hoses, 2 10 pump filter change, Maintenance Maintenance, 5 41 card, 5 59 Accumulator dump valve, Emergency Hydraulic systems, operation, Disposal, Machine, 2 12 Agitator, Emergency operation, Agitator emergency operation, Icons, Agitator gearbox, Transmission oil, Electrical components,...
Page 560 Index of key words Replacing the S transfer tube wear WALFORMplus threaded union, 5 12 sleeve, 5 117 Transfer gearbox, Transmission oil, Replacing the switching shaft bearing S transfer tube 5 20 (flanged bearing), 5 79 Adjusting, 5 131 Transfer tube, Emergency operation, Replacing the thrust ring and wear Measuring the wall thickness, 5 147...

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