Putzmeister BSA 1407 D5 Operating Instructions Manual

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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.

21−09−09

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

BSA 1407 D5

214490278

E Putzmeister Concrete Pumps GmbH 1994

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Page 1 Translation of the original Operating Instructions Stationary concrete pump BSA 1407 D5 Machine no. 214490278 21−09−09 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
Table of contents Electrical control devices ......3 — 20 3.6.1 Control cabinet with SPC display unit .
Page 10 Table of contents Starting up Visual checks ........4 —...
Page 11 Table of contents Transport, setting up and connection Transport ......... . . 5 —...
Page 12 Table of contents Pumping operations Preconditions ........6 —...
Page 13 Table of contents Glossary G–1 Symbols for concrete pumps in accordance with German Mechanical Engineering Association Standard (VDMA 24119) ........G —...
Page 15 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 16 Guide to the Operating Instructions BP01_001_0802EN...
Page 17 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 18 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 19 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 20 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 21 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 22 Guide to the Operating Instructions AusgleichsseiteEN...
Page 23 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 24 Safety regulations BP03_081_1701EN...
Page 25 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 26 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 27 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 28 Safety regulations 2.1.19 Place of work, working area, danger zone Mobile machines ab0005 Example Stationary machines ab0010 Example BP03_082_2101EN...
Page 29 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 30 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 31 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 32 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 33 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 34 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 35 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 36 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 37 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 38 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 39 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 40 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 41 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 42 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 43 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 44 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 45 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 46 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 47 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 48 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 49 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 50 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 51 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 52 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 53 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 54 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 55 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 56 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 57 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 58 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 59 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 60 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 61 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 62 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 63 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 64 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 65 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 66 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 67 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 68 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 69 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 70 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 71 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 72 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 73 Safety regulations There is a risk of injury at all points on the machine from slipping, tripping, bumping into things, etc. Use the handles and steps to climb into and out of the machine. It is forbidden to stand on the grille.
Page 74 Safety regulations 2.15.3 Cleaning with com- When the delivery line is being cleaned with compressed air, there 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 75 Safety regulations − The wash out adaptor must be fitted with a separate, large dump cock and a pressure gauge. − The pressure gauge must be kept under constant observation 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 76 Safety regulations AusgleichsseiteEN...
Page 77 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 78 General technical description BP02_001_0302EN...
Page 79 General technical description Overview Below you will find an overview of the most important components; these will then be described on the following pages. Left–hand side AP21_114_1708EN 1 Pos. Component Page Documentation accompanying the machine − Engine − Exhaust after treatment system Hydraulic pumps −...
Page 80 General technical description Right–hand side AP21_114_1708EN 2 Pos. Component Page Pressure gauge Output controller OPS/SPC control cabinet Magnetic switch distributor casing Cable remote control Machine rating plate Buzzer − Fuse box Pump control system Drive cylinder emergency operation Emergency operation transfer tube Centralized lubrication system AP21_114_1708EN...
Page 81 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 82 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 83 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 1407 D Height 2510...
Page 84 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 85 General technical description 3.3.2 Machine rating plate The following rating plate is attached to the machine: Betonpumpe BSA 1407 D5 214490278 BP22_830_1005EN 1 Designation Designation of the machine Machine model Machine number Maximum fluid pressure in the hydraulic system [bar]...
Page 86 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 87 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 88 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 89 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 90 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 91 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 92 General technical description 3.4.5 Agitator The hopper is equipped with a hydraulically driven agitator. The agitator performs two functions: − it improves the filling rate of the delivery cylinders; − it mixes the concrete. AP02_055_9710EN 1 Designation Hydraulic motor Agitator shaft Agitator helix Improving the The filling rate in the delivery cylinders should be as high as possible...
Page 93 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 94 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 95 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 96 General technical description 3.5.5 Centralized lubrica- The centralized lubrication system comprises a lubricant pump / tion system grease gun, lubricant distributors, relief valves and supply lines. AP02_908_1304EN 1 Designation Lubricant reservoir Lubricant pump Grease gun Lubricant distributor Agitator shaft bearings Transfer tube bearing Upper switch cylinder bearings Lower switch cylinder bearings...
Page 97 General technical description The centralized lubrication system supplies grease to the lubrication points connected to it. The lubrication points are lubricated in fixed cycles. Lubricant reservoir The lubricant reservoir may be filled up to the Max" marking through the filling nipple or from above through the filling opening. Note Note the following when filling the lubricant reservoir: Use only a grease listed in the lubricant recommendation table.
Page 98: Electrical Control Devices
General technical description Electrical control The electrical control devices and operating elements on this devices machine are described on the following pages. The summary at the start of this chapter will show you where the various control devices are located on the machine. The symbols used on the electrical con trol devices are described in one of the preceding sections.
Page 99: Control Cabinet With Spc Display Unit
General technical description 3.6.1 Control cabinet with You can control the functions of the machine from the control cabi SPC display unit net. SPC = Small Pump Control The SPC display enables you to determine the operating state of the machine.
Page 100 General technical description Continued Operating/ Pos. Meaning/function Comments control element Toggle switch Deactivate EMERGENCY STOP − 0 − Ac knowledge agitator/agitator safety cutout (RSA) Ignition−starter switch Diesel engine On − Off Toggle switch Open shut off valve − agitator − close shut off valve Toggle switch Agitator on...
Page 101 General technical description Right–hand view AP21_022_1704EN 2 Operating/ Pos. Meaning/function Comments control element Round socket, 4 pin Connection for vibrator optional Bush Connection for remote control/ Local control − Remote control Local control = replacement plug is plugged in AP21_022_1704EN...
Page 102 General technical description SPC display unit and operating elements AP21_022_1704EN 3 Operating/ Pos. Meaning/function control element Menu−driven operating states and adjustable functions SPC display are displayed in the SPC display. Button Function button for navigation and operation. System LED The LED of the display unit lights up when the control cabinet is supplied with power and flashes when the program is running.
Page 103 General technical description Special features of the control cabinet Starting up the pump If you have pressed the EMERGENCY STOP button, you may only after EMERGENCY start the pump up again as described below: STOP − Unlock the EMERGENCY STOP button by turning it. −...
Page 104 General technical description Forward pumping − 0 − The function of the Forward pumping Reverse pumping" Reverse pumping toggle switch depends on the local or remote control. − The replacement plug is plugged in for local control. The pump can be switched over using the Forward pumping 0 Reverse pumping"...
Page 105: Spc Display Unit
General technical description 3.6.2 SPC display unit The SPC display unit on the control cabinet has a graphical display and operating elements. The SPC display enables you to determine the operating state of the machine. Use the operating elements of the SPC display unit to navigate within the menu structure and apply settings.
Page 106 General technical description Appearance of the The symbols used in the SPC display appear differently depending symbols on the meaning. Colour / Appearance Meaning Background colours: Black Standard appearance Symbol colours: White Function is selected (switch or button pressed) Green Function is active Yellow Warning on the engine’s control dis...
Page 107 General technical description Menu structure The following pages show the password free section of the menu structure (example). A start screen is always displayed when the ma chine is started up. AP21_097_1703EN 1 AP21_097_1703EN...
Page 108 General technical description Pos. Display Function/meaning page The HOME menu is the main menu. Data and HOME main instruments are displayed here. Select this menu to display data and all in Expanded HOME struments. Select this menu to display the software ver Software information sion and firmware version.
Page 109 General technical description HOME menu The HOME menu is the main menu. Data and main instruments are displayed here. Function buttons in the HOME menu AP21_098_1703EN 1 Pos. Display Function/meaning The last selected start menu is opened by pressing Button button (1).
Page 110 General technical description All symbols in the menu bar AP21_098_1703EN 2 Pos. Symbol Function/meaning Back to the start menu This symbol is displayed regardless of the current menu. The symbol has no function in the HOME menu. Menu: Expanded HOME Submenu: Software information Submenu: Operating data Submenu: Engine fault code...
Page 111 General technical description Continued Switch EOC on/off S transfer tube switch−over: Soft, hard and auto Reset the trip" day counter This symbol is displayed in the following menus: Operating data, user settings AP21_098_1703EN...
Page 112 General technical description Instruments in the HOME menu AP21_098_1703EN 3 Pos. Display Function/meaning Cooling water tempera The cooling water temperature is displayed. ture [°C], analogue and digital Engine speed [rpm], The engine speed is displayed. analogue and digital Hydraulic fluid tempera The hydraulic fluid temperature is displayed.
Page 113 General technical description Symbols in the HOME menu AP21_099_1703EN 1 Note Depending on the equipment fitted to your machine, some of the functions illustrated may not be present. The symbol is not lit if a function is not present. AP21_099_1703EN...
Page 114 General technical description Note The warning strategy of the exhaust after treatment system complies with the relevant national codes of practice. The following emissions−relevant faults are therefore displayed: Fill level of the DEF container DEF quality, DEF manipulation, DEF hardware DPF regeneration, DPF crystallisation AP21_099_1703EN...
Page 115 General technical description Warning triangle deactivated Symbol is shown in grey, as long as the escalation stages have not yet been reached on the exhaust after treatment system. Warning triangle, yellow Symbol lights up yellow in the following cases: − Once the tank content is between < 10% and > 5%, −...
Page 116 1. This symbol flashes and is displayed in red if a fault has occurred in the CAN bus (CAN1 = connection between controller and display). You need to have the fault rectified by a Putzmeister service techni cian. AP21_099_1703EN...
Page 117 This symbol flashes and is displayed in red if a fault has occurred in the CAN bus (CAN2 = connection between engine control unit and controller). You need to have the fault rectified by a Putzmeister ser vice technician. Sensors This symbol is displayed in grey if no fault has occurred in the mag netic switches (see the magnetic switch distributor casing"...
Page 118 General technical description EMERGENCY STOP This symbol is displayed in grey if no EMERGENCY STOP button has been pressed or if the EMERGENCY STOP has been acknowledged. This symbol flashes and is displayed in red if an EMERGENCY STOP button has been pressed. Agitator safety cutout (RSA) This symbol is displayed in grey if the agitator safety cutout has not been pressed or if the agitator safety cutout has been acknowl...
Page 119 General technical description This symbol is displayed in grey if EOC is switched off. Symbol lights up green if EOC is switched on. Delivery rate This symbol is displayed in grey if the concrete pump is switched off. The delivery rate is displayed in numbers if the concrete pump is switched on and the Forward pumping"...
Page 120 General technical description Vibrator This symbol is displayed in grey if the vibrator is switched off. This symbol is displayed in white if the concrete pump and the vi brator are switched off but the Pump off Vibrator on" toggle switch has been switched to Vibrator on"...
Page 121 General technical description Fill level warning symbol for the DEF container (green) This symbol lights up green if the container content is between < 12% and > 10%. Fill level warning symbol for the DEF container (yellow) This symbol lights up yellow if the container content is between <...
Page 122 General technical description Warning symbol for DEF quality and exhaust gas treatment (grey) This symbol lights up grey if the DEF quality and exhaust gas treat ment are good. Warning symbol for DEF quality and exhaust gas treatment (green) This symbol lights up green if the DEF quality and exhaust gas treat ment are good.
Page 123 General technical description Warning symbol for DEF quality Abbreviations used: Q" = Quality M" = Manipulation H" = Hardware = components in the exhaust after treatment system C" = Crystallisation DEF quality Symbol lights up green if the DEF quality and exhaust gas treatment are good.
Page 124 General technical description Note Crystallisation is monitored by the SCR system. As soon as crystallisation is detected, you must implement counter measures by selecting the operating modes (Heat mode or stand still). DEF crystallisation Symbol lights up green if no crystallisation is detected and passive DPF regeneration (heat mode) takes place during engine operation.
Page 125 General technical description Warning symbol for DPF regeneration (grey) Symbol lights up grey when DPF regeneration is not required. Warning symbol for DPF regeneration (green) Symbol lights up green and passive DPF regeneration (heat mode) takes place during engine operation. Warning symbol: DPF regeneration (yellow) Symbol lights up yellow if active standstill DPF regeneration is re quired.
Page 126 General technical description Note The engine oil must be changed every 500 hours or after the DPF has been regenerated several times, and if the warning symbol En gine oil change required" is displayed. Warning symbol for engine oil change required (yellow) Symbol lights up yellow if the engine oil needs to be changed.
Page 127 General technical description Expanded HOME The Expanded HOME" menu is an expanded display of the HOME menu main menu. Data and additional instruments are displayed here. Function buttons in the expanded HOME menu AP21_100_1703EN 1 Pos. Display Function/meaning The last selected start menu is opened by pressing Button button (1).
Page 128 General technical description Instruments in the expanded HOME menu AP21_100_1703EN 2 Pos. Display Function/meaning Cooling water tempera The cooling water temperature is displayed. ture [°C], analogue Engine oil pressure [bar], The engine oil pressure is displayed. analogue Engine speed [rpm], ana The engine speed is displayed.
Page 129 General technical description All symbols in the menu bar Note You can find a description of all symbols in the menu bar, regardless of the current menu, in the section All symbols in the menu bar". Symbols in the expanded HOME menu AP21_100_1703EN 3 Note You can find a description of the symbols in the expanded HOME...
Page 130 General technical description Software information In this menu, you can read off the software versions of the control systems. Display Function/meaning Putzmeister Small Pump Control Generation 2 Controller Display V100 Version 1.0.0 AP21_030_1511EN 1 Pos. Display Function/meaning The software versions of the control systems are dis Software versions played.
Page 131 General technical description Operating data The operating data for the machine are displayed in two tables in this menu, with the total values in the total" table on the left and the current values in the trip" table on the right. AP21_031_1703EN 1 Pos.
Page 132 General technical description AP21_031_1703EN 2 Continued Pos. Display Function/meaning The current stroke time 2 is displayed. Stroke time 2 [s] Stroke time 2: For example, the time required for drive piston 2 to move towards the water box. The current stroke time 1 is displayed. Stroke time 1 [s] Stroke time 1: For example, the time required for drive piston 1 to move towards the cylinder base.
Page 133 General technical description Fault memory The fault codes for the most recent faults are displayed in this menu. AP21_032_1511EN 1 Pos. Display Function/meaning Fault The fault code is displayed. The last selected HOME menu can be opened by Momentary contact switch pressing button (2).
Page 134 General technical description User settings In this menu, you can set setpoint values for the pump output and the fill level of the delivery cylinders and compare them with the actual values that have been achieved. The delivery rate can be calculated with the operating data specified above.
Page 135 General technical description Function buttons in the user settings menu AP21_033_1703EN 1 Pos. Display Function/meaning The last selected HOME menu can be opened by Button pressing button (1). Parameters are selected by pressing up or down on the direction button (2). Direction key The value of the parameter is set by pressing left or right on the direction button (2).
Page 136 General technical description AP21_033_1703EN 2 Pos. Display Function/meaning The specified pump output or the fill level of the deliv Setpoint values ery cylinders is displayed. The pump output or fill level of the delivery cylinders that has been achieved is displayed. Actual value (adjustable) The two parameters are used to calculate the delivery rate [m...
Page 137 General technical description Continued Pos. Display Function/meaning In the event of a fault: The setpoint and actual values for the stroke time are Stroke time [s] displayed. In the event of a fault: The simulated engine speed is displayed in numbers. Engine speed [rpm], digital Fill level of the delivery cyl The setpoint and actual values for the Fill level of the...
Page 138 General technical description Lubrication You can begin a manual lubrication cycle or set the number of strokes until the next lubrication in this menu. Parameters such as the number of strokes performed since the last lubrication and the number of strokes until the next lubrication are displayed. Function buttons in the lubrication menu AP21_048_1703EN 1 Pos.
Page 139 General technical description All symbols in the menu bar AP21_048_1703EN 2 Pos. Symbol Function/meaning Back to the start menu This symbol is displayed regardless of the current menu. The symbol has no function in the HOME menu. Manually activate a lubrication cycle. Reset to the factory settings.
Page 140 General technical description AP21_048_1703EN 3 Pos. Display Function/meaning Number of strokes, ana The number of strokes until the next lubrication is dis logue played. The number of strokes until the next lubrication is dis Number of strokes, digital played in numbers. The number of strokes performed since the last lu Number of strokes, digital brication is displayed in numbers.
Page 141 General technical description Inputs and outputs This menu is used to display the number of active inputs and out puts. It also allows you to reset the position values for the S transfer tube, for example after installing the resolver. Function buttons in the inputs and outputs menu AP21_101_1703EN 1 Pos.
Page 142 General technical description All symbols in the menu bar AP21_101_1703EN 2 Pos. Symbol Function/meaning Back to the start menu This symbol is displayed regardless of the current menu. The symbol has no function in the HOME menu. The position values for the S transfer tube are reset to the factory settings.
Page 143 General technical description AP21_101_1703EN 3 Pos. Display Function/meaning An overview of all inputs is displayed. The active in IN = inputs, analogue puts are displayed in green. Sensor faults on the delivery pump are displayed: Sensor fault = Z1S, Z2S, Z1 rod, Z2 rod, Z1 ground and S transfer tube position Z1B, sValve sensor...
Page 144 General technical description 3.6.3 Ergonic Output Con- The Ergonic Output Control (EOC) enables you to save the selected trol (EOC) engine speed. You can switch the Ergonic Output Control on and off using the SPC display unit. HOME menu AP21_102_1703EN 1 Pos.
Page 145: Ergonic Output Control (Eoc)
General technical description Special features of Ergonic Output Control Switch Ergonic Output If the display is defective or de−energised or a CAN bus fault has Control on/off occurred, the Ergonic Output Control will be switched on automati cally. If the display is functioning properly, the Ergonic Output Control will be switched off after the control system is restarted (switching on the ignition).
Page 146 General technical description Ergonic Output Control The factory−set engine speed replaces any saved EOC speed. switched off If the Ergonic Output Control is switched off, the pump control sys tem will behave in the following way: Concrete pump start The engine will be started up at the factory−set engine speed if the current engine speed when the concrete pump is started up is lower than the preset engine speed.
Page 147: Fuse Box
General technical description 3.6.4 Fuse box The fuse box is located underneath the OPS/EGD control cabinet". The operating elements to enable and start DPF regeneration are located on the side, as is the momentary−contact switch to override engine−related faults. Right–hand view AP02_988_1501EN 1 Operating/ Pos.
Page 148 General technical description Special features of the fuse box Note Abbreviations used: EAT = Exhaust After Treatment (after treatment of exhaust gas) DEF = Diesel Exhaust Fluid (urea solution used in exhaust gas treat ment, e.g. AdBlue") DPF = Diesel Particle Filter DOC = Diesel Oxidation Catalyst SCR = Selective Catalytic Reduction Locally latched toggle...
Page 149 General technical description Note When the DPF regeneration" warning symbol lights up in yellow in the EDG of the OPS/EDG control cabinet", you need to start the re generation procedure/stationary regeneration manually" at the fuse box. The regeneration procedure can only be started manually" if the fol lowing conditions are met: You have positioned the machine in the open, on terrain with a sufficient distance from other machines, combustible materials...
Page 150 General technical description Manually starting the Start the DPF regeneration procedure at the fuse box as follows: DPF regeneration pro − Switching the toggle switch from Pumping operations" to Enable cedure DPF regeneration" interrupts pumping operations and enables the DPF regeneration procedure. The EMERGENCY STOP status is triggered at the same time.
Page 151 General technical description Manually stopping the Stop the DPF regeneration procedure at the fuse box as follows: DPF regeneration pro − Pressing the toggle switch DPF regeneration On − Off" again in cedure terrupts the DPF regeneration procedure or stops the procedure. −...
Page 152: Cable Remote Control
General technical description 3.6.5 Cable remote control The most important control functions for the pump are gathered together on the cable remote control, so that you can control the operation of the pump from here. AP02_905_1304EN 1 Operating/control element Meaning/function Comments Momentary contact switch EMERGENCY STOP...
Page 153 General technical description Special features of the cable remote control Starting up the pump The red EMERGENCY STOP activated" indicator lamp on the after EMERGENCY control cabinet lights up and the green Pump running" indicator STOP lamp flashes if you have pressed the EMERGENCY STOP button. You can only restart the pump as described below: −...
Page 154: Emergency Stop Button
General technical description 3.6.6 EMERGENCY STOP EMERGENCY STOP buttons are fitted to the following machine com button ponents: − the cable remote control − the right hand side of the machine, near the operating elements. Caution Familiarize yourself with the positions of the EMERGENCY STOP but tons on your machine.
Page 155 General technical description The following actions are triggered when you press one of the EMERGENCY STOP buttons: − the EMERGENCY STOP symbol lights up red on the EPS/EGD control cabinet, − variable main pumps swing back, the delivery pistons come to a halt, −...
Page 156: Agitator Safety Cutout (Rsa)
General technical description 3.6.7 Agitator safety cutout The agitator safety cutout consists of a transponder and an evalu (RSA) ation device with reading head. As soon as you open the grille, the radio link between the transponder and the reading 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−ener gized, i.e.
Page 157 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 information: The green LED flashes for 8 seconds during the initialization pro cess.
Page 158: Magnetic Switches Distributor Casing
General technical description 3.6.8 Magnetic switches The distributor casing for the magnetic switches is located beneath distributor casing the control cabinet. AP02_853_1202EN 1 Belongs Control element Meaning/Function with no.: Yellow LED Magnetic switch (rod side), drive cylinder II Yellow LED Magnetic switch (rod side), drive cylinder I Female connector Not assigned...
Page 159 Distributor casing status lights up continuously The distributor casing is ready for operation. does not light up The Putzmeister operating sys tem is not supplied with a volt age. Note Additional LEDs are located on the magnetic switch connector (see page 3 83).
Page 160 General technical description Stroke correction Electronic stroke correction on this machine takes place as required. As soon as the piston side magnetic switch in drive cylinder 1 is trig gered, it always resets the set time to zero. If this magnetic switch is no longer triggered, the set time (e.g.
Page 161: Magnetic Switch Connector
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 162 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 163: Hydraulic Control Devices
General technical description Hydraulic control The hydraulic control devices and operating elements on this ma devices chine are described on the following pages. The overview at the start of this chapter will show you where the various control devices are located on the machine.
Page 164: Output Controller
General technical description 3.7.1 Output controller The output controller (1) is used to open/close an adjustment valve, so that the output is increased or reduced. If the output controller (1) shows min", the delivery cylinders remain stationary − the concrete pump is switched off.
Page 165: Water Pump Lever
General technical description 3.7.2 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 166: Pump Control System
General technical description 3.7.3 Pump control system The hydraulic control valves are built into the pump control system. They are only for emergency manual operation of the machine when the control system fails. AP21_076_1609EN 1 Pos. Designation Emergency operation transfer tube Drive cylinder emergency operation AP21_076_1609EN...
Page 167: Agitator Emergency Operation
General technical description 3.7.4 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 168: Pressure Gauge
General technical description 3.7.5 Pressure gauge The hydraulic pressure of the hydraulic pump is shown on the pressure gauge. AP02_063_0308EN 1 3.7.6 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 169: Other Components
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 170: Flushing Water Pump
General technical description 3.8.1 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 171 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 172: Vibrator
General technical description 3.8.2 Vibrator The vibrator is bolted to the grille. It causes the grille to vibrate and thus prevents bridges forming on the grille, particularly in the case of very stiff concrete. The vibrator is electrically driven; the connecting plug must be plugged into the appropriate socket on the control cabinet for this to work.
Page 173: Exhaust After Treatment System
General technical description 3.8.3 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 174 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 175 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 176 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 177 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 178 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 179 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 180 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 181 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 182 General technical description AusgleichsseiteEN...
Page 183 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 184 Starting up AP13_015_0303EN...
Page 185 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 186 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 187 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 188 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 189 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 190 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 191 Starting up 4.2.1 Switching on Before switching on the machine, you must set up the machine cor the machine rectly, have the control cabinet connected to the electrical power supply and must set up the cable remote control for use. You can find information on this in the chapter entitled Transport, setting up and connection".
Page 192 Starting up Note To operate the machine locally, the Local control" connector must remain plugged into the Local control − remote control" socket on the control cabinet. AP13_073_1111EN 2 Designation Local control" connector Plug in the Local control" connector. " Switch on the diesel engine using the ignition starter switch.
Page 193 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 194 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 195 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 196 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 197 Starting up AP13_075_1610EN 1 Pos. Designation Transponder (on the grille) Green and red LEDs Acknowledge agitator or agitator safety cutout on the control cabinet Reading head (on the hopper − example illustration) Open the grille with the concrete pump running. "...
Page 198 Starting up 4.3.4 Acknowledging the The agitator is secured against unexpected restarts. When the ma agitator safety cutout chine is started up after the agitator safety cutout has been actuated, the agitator safety cutout must be acknowledged before the concrete pump can be switched back on.
Page 199 Starting up AP13_076_1610EN 1 Pos. Designation Acknowledge agitator or agitator safety cutout on the control cabinet Actuate the Acknowledge agitator or agitator safety cutout" " toggle switch on the control cabinet. AP13_076_1610EN...
Page 200 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 201 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 202 Starting up 4.3.6 Agitator The agitator hopper grille must always be closed when the pump is in operation. 20203003 Designation Agitator On − agitation direction away from the delivery cylinder (1a) Agitator Off Agitator On − agitation direction towards the delivery cylinder (1b) Actuate the toggle switch on the control cabinet and check the "...
Page 203 Starting up 4.3.7 Flushing water pump Depending on the machine specification, it may be equipped with either a Hypro WP 50 or a CRK 4−160. To prevent damage, never run the flushing water pump without water. You may, however, perform a short function test lasting a few seconds without the water being connected.
Page 204 Starting up 4.3.8 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 205 Starting up 4.3.9 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 206 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 207 Starting up AP13_122_1709EN 1 Example illustration Pos. Designation Ignition starter switch: Diesel engine On−Off Switch off the ignition (1). " å The control unit saves required data during the run−down time (approximately two minutes). AP13_122_1709EN...
Page 208 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 209 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 210 Transport, setting up and connection AP06_001_1007EN...
Page 211 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 212 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 213 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 214 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 215 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 216 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 217 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 218 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 219 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 220 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 221 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 222 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 223 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 224 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 225 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 226 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 227 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 228 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 229 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 230 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 231 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 232 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 233 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 234 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 235 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 236 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 237 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 238 Transport, setting up and connection AP06_017_1008EN 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 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.
Page 239 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 240 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 241 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 242 Pumping operations AP07_026_9710EN...
Page 243 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 244 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 245 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 246 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 247 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 248 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 249 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 250 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 251 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 252 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 253 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 254 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 255 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 256 Pumping operations 6.8.1 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 257 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 258 Pumping operations 6.8.2 Blockages 11000601 Designation Wedged aggregate Cement paste Boundary layer The following faults can lead to blockages: − delivery line is insufficiently wetted − transfer tube is leaking − lines are leaking − leavings in the transfer tube and delivery line −...
Page 259 Pumping operations 6.8.3 Breaks in pumping You should avoid breaks in pumping as far as possible, as the con crete in the delivery line can start to set, or can become segregated due the the vibrations of the machine. Note the following points if breaks are unavoidable: −...
Page 260 Pumping operations 6.8.4 Engine Do not exceed the permissible engine speed specified in the ma chine card and on the machine rating plate. Always set the engine speed higher than the vibrating speed. Do not shut down the engine immediately after periods of heavy engine loading, but first allow it to cool down at idling speed.
Page 261 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 262: Exhaust After Treatment System
Pumping operations 6.8.6 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. Particularly during the DPF regeneration procedure/stationary regen eration, extremely high exhaust gas and surface temperatures arise at the exhaust after treatment system.
Page 263 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 takes approx. 40 min utes with exhaust gas temperatures of approx.
Page 264 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 265 Pumping operations Note The engine oil becomes diluted with fuel after each stationary regen eration. The quality of the engine oil is monitored for this reason. The engine oil must be changed as soon as the yellow Engine oil change required" warning symbol lights up in the EGD. Note When the DPF regeneration"...
Page 266 Pumping operations 6.8.7 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 267 Pumping operations Cleaning Concrete leavings that are deposited inside the delivery line or transfer tube can cause damage, will accumulate and reduce the cross section. A clean delivery line and transfer tube is therefore in dispensable if you wish to be able to start pumping without problems on the next job.
Page 268 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 269 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 270 Pumping operations 6.9.1 Preparations We recommend that you carry out the preparations described below for cleaning in good time to allow you to clean the delivery line and the concrete pump directly the site use is completed. Sponge balls and other accessories 10003401 Sponge pig...
Page 271 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 272 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 273 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 274 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 275 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 276 Pumping operations 6.9.2 Delivery line There are a number of options for cleaning a delivery line. Some of the factors affecting which cleaning method you use include how the concrete pump has been used and what equipment you have avail able.
Page 277 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 278 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 279 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 280 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 281 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 282 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 283 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 284 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 285 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 286 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 287 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 288 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 289 Pumping operations 6.9.4 Post-cleaning Once the delivery line, hopper, delivery cylinders and S transfer procedure tube have been washed out, you must thoroughly rinse down all other parts of the machine that have come into contact with con crete. Concrete that is not washed off immediately can attack the paint, especially if aggressive concrete additives have been used.
Page 290 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 291 Pumping operations 6.10 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 292 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 293: 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 294 Glossary BP14_001_0501EN...
Page 295: 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 296 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 297 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 298 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 299 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 300 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 301: 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 302 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 303 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 304 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 305 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 306 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 307 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 308 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 309: 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 310 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 311 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 312 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 313 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 314 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 315 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 316 Glossary BP14_002_0501EN...
Page 317: 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 318 Index of key words 8 — II...
Page 319 Index of key words Checks Copyright, Function checks, Corner bearing load, 2 30 Abbreviations, Visual checks, G 15 Crawler track, Cleaning, Accessories and attachments, 6 25 2 15 Catch basket, 6 29 After Sales Service personnel, Defini- Cleaning agents, 2 49 tion of terms, Compressed air, 2 50...
Page 320 Index of key words Description of the functions, Extensions, End hose and placing 3 10 Warning symbol for DEF quality and boom, exhaust gas treatment (yellow), 3 44 2 13 Centralized lubrication system, 3 18 Warning symbol for DPF regeneration Change over, 3 13 (green),...
Page 321 Index of key words High–pressure water cleaning, Locking, 6 38 3 26 Requirements, 2 16 Responsibility of the machine operator, High–voltage lines, Lubrication menu, Symbols in the 2 22 2 16 menu bar, 3 61 Clearances, 2 22 Place of work, High voltage warning device, 2 24 Lubrication points,...
Page 322 Index of key words Preconditions, High−voltage lines, 2 22 Hydraulic fluid overheating, 3 39 Pumping, 6 13 Minimum clearance from pits, 5 13 Inputs and outputs, 3 63 Safety, 2 45 Space for truck mixers, 5 11 Instruments in the expanded HOME menu, 3 50 Saturated mix,...
Page 323 Index of key words Supports, 2 31 Switches off the pump, 4 21 Warning triangle, orange, Power re- Symbols, duction stage 1, 3 37 Symbols for the control system, Warning triangle, red, Power reduc- tion stage 2, 3 37 Wash–out adaptors, 6 30 Water, 2 51...
Page 325 Translation of the original Operating Instructions Stationary concrete pump BSA 1407 D5 Machine no. 214490278 21−09−09 The paper on which this document is printed is 100% chlorine free E Putzmeister Concrete Pumps GmbH 1994...
Page 326 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 327 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 328 BP00_030_0911EN...
Page 329 Table of contents Table of contents Guide to the Service Instructions Foreword ......... . . 1 —...
Page 330 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 331 Table of contents Maintenance Daily tasks ......... . 5 —...
Page 332 Table of contents Maintenance cards 00−001 Visual checks ....... 03−002 Function checks .
Page 333: 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 334 Guide to the Service Instructions BP01_009_1011EN...
Page 335: 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 336 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 337: 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 338 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 339 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 341: 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 342 Safety regulations BP03_083_1701EN...
Page 343: 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 344: Requirements For Special Work
Safety regulations Requirements for spe- In the capacity of operator, it is your responsibility to provide all the cial 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 speci- fications for the replacement of parts and equipment.
Page 345 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 ade- quate lifting capacity. Never stand under suspended loads. Attachment of loads and signalling to crane operators should only be entrusted to experienced personnel.
Page 346: Welding
Safety regulations Welding Only carry out welding, flame cutting and grinding operations on the machine once this has been expressly approved by the manufactu- rer. Only qualified personnel may carry out welding work in line with ma- nufacturer 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 347: Working On The Placing Boom
Safety regulations Working on the pla- Only carry out maintenance and repair work on the placing boom if cing boom the placing boom is folded or properly supported, the engine is swit- ched 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 348: 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 349: 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 machi- nes operated on the site power supply, see also section 2.8.3, entit- led “Power at the construction site”. wz0235 Machine components which are to undergo maintenance work must be de-energized.
Page 350: 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 inter- nal moving parts. Protection against damaging dust deposits. –...
Page 351: Hydraulic Systems
Safety regulations Hydraulic systems 2.9.1 General Work on hydraulic systems must only be carried out by qualified per- sonnel. Always wear your personal protective equipment when carrying out work on the hydraulic system. Escaping fluid is toxic and can pene- trate the skin.
Page 352: 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 lowe- ring, etc.
Page 353: 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–opera- ted heating systems only in adequately ventilated premises. Before starting up the engine in enclosed spaces, make sure that there is adequate ventilation and direct the exhaust gases away from the place of work.
Page 354: 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 355 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 356 Safety equipment BP15_001_1202EN...
Page 357 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 358 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 359 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 360 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 361 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 362 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 363 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 364 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 365 Safety equipment 3.3.2 Function check AP15_003_1609EN 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 366 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 367 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 control cabinet before the concrete pump can be switched back on.
Page 368 Safety equipment AP15_003_1609EN 3 Pos. Designation Toggle switch on the control cabinet: Acknowledge the agitator safety cutout Activate the Acknowledge the agitator safety cutout" toggle " switch. AP15_003_1609EN...
Page 369 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 370 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 371 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 372 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 373 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 374 Safety equipment AusgleichsseiteEN...
Page 375 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 376 Special modes of operation AP16_001_1609EN...
Page 377 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. Note For the location of the pump control system, refer to the overview at the start of the chapter General technical description".
Page 378 Special modes of operation Operating the OPS pump control system Drive cylinder emerg In order to be able to move the piston to the cylinder end position, ency operation operate the drive cylinder emergency operation (2). Emergency operation In order to be able to switch over the transfer tube, keep the drive transfer tube cylinder emergency operation (2) pressed, while at the same time operating the transfer tube emergency operation (1).
Page 379 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 380 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 381 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 382 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 383 Special modes of operation Press the drive cylinder emergency operation device to the left " or right. å The corresponding delivery cylinder starts to move. On machines with a single−circuit hydraulic system", you can switch over the transfer tube as follows: Press and hold the drive cylinder emergency operation device.
Page 384 Special modes of operation AusgleichsseiteEN...
Page 385: 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 386 Maintenance BP09_001_9405EN...
Page 387: 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 388: 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 389: 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 390: 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 391: 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 392 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 393: 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 394: 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 395 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 396: 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 397 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 398: 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 399: 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 400 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 401: 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 402 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 403: 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 404: 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 405 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 406: 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 407: 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 408: 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 409 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 410 Maintenance BP09_013_1205EN...
Page 411 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 412 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 413 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 414 Maintenance card 03−002 Page 2 of 2 WK03_002_1109EN...
Page 415 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 416 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 417 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 418 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 419 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 420 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 421 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 422 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 423 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 424 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 425 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 426 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 427 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 428 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 429 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 430 Maintenance card 04−013 Seite 6 von 6 WK04_013_1109EN...
Page 431 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 432 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 433 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 434 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 435 No further maintenance cards required. No special tools required. Note You must rectify damage to the delivery pistons immediately. Putzmeister accepts no warranty claims for damage to the machine resulting from failure properly to observe the maintenance regula tions. Danger Secure the working area.
Page 436 Maintenance card 06−023 Page 2 of 6 You will have to start and stop the machine a number of times as you replace the delivery pistons . The operations necessary for this are described below and must be carried out conscientiously. Shutting down Proceed as follows to shut down the machine: the machine...
Page 437 Maintenance card 06−023 Page 3 of 6 Piston replacement Pistons are replaced from the water box. Danger Always shut the machine down before you reach into the water box. 10600301 Piston rod flange Fastening bolts Securing wire Delivery piston Spacer flange Shut the machine down.
Page 438 Maintenance card 06−023 Page 4 of 6 Removing a piston 10600701 Fastening bolts Remove the wire clips from the fastening bolts and remove the " bolts from the spacer flange. Shift the unbolted delivery piston away from the spacer flange, "...
Page 439 Maintenance card 06−023 Page 5 of 6 Start the machine up. " Set the toggle switch on the control cabinet to reverse " pumping. Switch the concrete pump on at a very low output. " å The delivery piston is withdrawn completely from the delivery cylinder.
Page 440 Maintenance card 06−023 Page 6 of 6 Start the machine up. " Switch the concrete pump on at a very low output. " å The new delivery piston is pushed very slowly into the delivery cylinder. Switch the pump off before the fastening bolts for the delivery "...
Page 441 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 442 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 443 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 444 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 445 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 446 Maintenance card 07−069 Page 6 of 6 WK07_069_1109EN...
Page 447 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 448 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 449 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 450 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 451 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 452 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 453 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 454 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 455 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 456 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 457 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 458 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 459 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 460 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 461 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 462 Maintenance card 07−070 Page 16 of 16 WK07_070_1109EN...
Page 463 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 464 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 465 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 466 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 467 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 468 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 469 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 470 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 471 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 472 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 473 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 474 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 475 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 476 Maintenance card 07−071 Page 14 of 14 WK07_071_1109EN...
Page 477 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 478 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 479 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 480 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 481 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 482 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 483 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 484 Maintenance card 07−072 Page 8 of 8 WK07_072_1109EN...
Page 485 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 486 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 487 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 488 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 489 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 490 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 491 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 492 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 493 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 494 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 495 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 496 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 497 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 498 Maintenance card 07−074 Page 6 of 6 WK07_074_1109EN...
Page 499 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 500 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 501 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 502 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 503 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 504 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 505 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 506 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 507 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 508 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 509 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 510 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 511 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 512 Maintenance card 07−075 Page 14 of 14 WK07_075_1109EN...
Page 513 Maintenance card 07−078 Seite 1 von 2 07–078 Resolver on the switching This maintenance card describes how to fit the resolver on the shaft switching shaft. Note There are specific risks of accidents associated with maintenance, inspection and repair work. For this reason, read the chapter Safety regulations"...
Page 514 Maintenance card 07−078 Seite 2 von 2 WK07_078_1304EN 1 Designation Connecting cable Resolver Magnetic sensor Switch lever Switch cylinders Fit the resolver (2) as shown in the graphic. " å The resolver is located in its electrical middle position. Maintain the reacting distance a" (a = 8 +/− 4 mm). "...
Page 515 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. Note There are specific risks of an accident associated with maintenance, inspection and repair work.
Page 516 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. Note The lubrication interval is specified for normal operation.
Page 517 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 518 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 519 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 520 If the operating pressure is higher than 130 bar, you must ask Putzmeister what the minimum wall thickness is. WK10_007_1109EN...
Page 521 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 522 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 523 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 524 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 525 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 526 Index of key words 6 — II...
Page 527 Index of key words Intermediate rings on the transition liner, Replacing, 5 82 Accumulator dump valve, Emergency Electrical components, operation, Electrical power, Agitator, Emergency operation, Power at the construction site, Liability, Exclusion, Agitator emergency operation, Emergency operation Lubricant analysis, 5 17 Agitator gearbox, Transmission oil, Agitator, Lubricant recommendation...
Page 528 Index of key words Measuring the wall thickness, Safety equipment, Transmission oil 5 137 Machines with S transfer tube, 5 131 Active safety functions, Agitator gearbox, 5 20 Overview, Rotor gearbox, 5 20 Passive safety functions, Slewing gear transmission, 5 20 Plates, 3 17 Transfer gearbox,...

Putzmeister BSA 1407 D5 Operating Instructions Manual

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