Putzmeister BSF 47-5.16 H Operating Instructions Manual
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Putzmeister BSF 47-5.16 H Operating Instructions Manual

Truck-mounted concrete pump
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Table of Contents

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Operating Instructions
for machine operator and maintenance staff
always keep by the machine
Translation of the original instructions
Truck-mounted concrete pump
BSF 47-5.16 H
Machine no.
210110691
2018-09-19
The paper on which this document is printed is 100% chlorine-free
© Putzmeister Concrete Pumps GmbH 2018

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Summary of Contents for Putzmeister BSF 47-5.16 H

  • Page 1 Translation of the original instructions Truck-mounted concrete pump BSF 47-5.16 H Machine no. 210110691 2018-09-19 The paper on which this document is printed is 100% chlorine-free © Putzmeister Concrete Pumps GmbH 2018...
  • Page 2 Britain Carrwood Road GB−Chesterfield +44−1246−26 00 77 PMUK www.putzmeister.co.uk Derbyshire S41 9QB Türkiye +90−282−735−1000 Putzmeister Makine Sanayi ve Tic. A. pm@putzmeister.com.tr G.O. Pa a Mah. Nam k Kemal Bulvar No: 6 +90−282−738−1001 www.putzmeister.com.tr 59500 Çerkezköy / TEK +1−262−886−3200 Putzmeister America pmr@putzam.com...
  • Page 3 Translation of the original instructions ‫الأصلي‬ ‫التشغيل‬ ‫دليل‬ ‫ترجمة‬ Превод на оригиналното „Ръководство за работа“ Překlad originálního návodu k obsluze Oversættelse af den originale driftsvejledning Übersetzung der Originalbetriebsanleitung Μετάφραση του πρωτότυπου των οδηγιών λειτουργίας Traducción del manual de instrucciones original Originaalkasutusjuhendi tõlge Alkuperäisen käyttöohjeen käännös Traduction de la notice originale...
  • Page 4 Operating Instructions 210110691_2018-09-19_EN...

  • Page 5: Table Of Contents

    Table of contents . . . Table of contents Guide to the Operating Instructions ........1 — 1 Foreword ......................... 1 — 3 Icons and symbols ......................1 — 4 1.2.1 Layout of warning notices ....................1 — 5 Safety regulations ..............2 —...
  • Page 6 Table of contents . . . 2.3.10 Accessories and attachments ..................2 — 15 2.3.11 Changes to the machine ....................2 — 15 Exclusion of liability ......................2 — 16 Personnel ........................2 — 16 2.5.1 Requirements ........................2 — 16 2.5.2 Qualifications ........................
  • Page 7 Table of contents . . . 2.12.5 Procedure in storms ......................2 — 36 2.12.6 Concreting in cold weather ....................2 — 37 2.13 Delivery line systems ...................... 2 — 37 2.13.1 Suitable delivery lines ..................... 2 — 37 2.13.2 Securing delivery lines ....................
  • Page 8 Table of contents . . . General conditions for using a concrete pump ..............3 — 26 3.4.1 Service life ........................3 — 27 3.4.2 Site of use ........................3 — 27 3.4.3 Height of job ........................3 — 27 3.4.4 Operating temperature ....................
  • Page 9 Table of contents . . . 4.1.3 Driving ..........................4 — 5 Hand signals for driving ....................4 — 7 4.2.1 Hand signal for stopping ....................4 — 7 4.2.2 Hand signal for turning left ....................4 — 7 4.2.3 Hand signal for turning right ....................
  • Page 10 Table of contents . . . 5.6.3 Danger zone ........................5 — 69 5.6.4 Independent retracting of the hydraulic cylinders ............5 — 73 5.6.5 Spontaneous slewing of the placing boom ..............5 — 74 5.6.6 Uncontrolled boom movements ..................5 —...
  • Page 11 Table of contents . . . 5.11 Cleaning .......................... 5 — 118 5.11.1 Concrete residue ......................5 — 120 5.11.2 Compressed air cleaning ....................5 — 121 5.11.3 Operate the high-pressure water pump ................5 — 122 5.11.4 Preparations for cleaning ....................5 —...
  • Page 12 A — 8 Operating Instructions 210110691_2018-09-19_EN...
  • Page 13 In this chapter you will find notes and information that will help you use these Operating Instructions. If you have any queries, please write to us in confidence at the address given below, or contact the relevant branch or works agency. Putzmeister Concrete Pumps Abteilung Kundendienst Max-Eyth-Straße 10 72631 Aichtal, Germany...
  • Page 14 1 — 2 Operating Instructions 210110691_2018-09-19_EN...

  • Page 15: Guide To The Operating Instructions

    Guide to the Operating Instructions Foreword These Operating Instructions aim to help you to familiarise yourself with the machine and make use of its intended applications. The Operating Instructions contain important information on how to operate the machine safely, properly and economically. Your observ‐ ance of these instructions will help avoid dangers, reduce repair costs and downtimes and increase the reliability and life of the machine.

  • Page 16: Icons And Symbols

    Violations will result in a claim for damages. All rights reserved in the event of the grant of a patent, utility model or design. © Putzmeister Concrete Pumps GmbH 1994 Icons and symbols The following icons and symbols are used:...

  • Page 17: Layout Of Warning Notices

    Guide to the Operating Instructions Icon/symbol/ Meaning designation Fault rectification – Instructions to be carried out in accordance with fault messages. View additional steps. For example, “Contact a qualified electrician”. The requirements or tools outlined below must be ✓ met or available. Tests or inspections have been passed.
  • Page 18 Guide to the Operating Instructions WARNING Indicates a dangerous situation in which an accident resulting in se‐ rious or fatal injuries may occur. ▶ After identifying the risk, instructions are set out which are inten‐ ded to avoid or remedy the risk. CAUTION There is a risk of injury to the entire body, however there is no risk of serious or fatal injuries.
  • Page 19 Safety regulations These safety regulations correspond to the “Terms, definitions, re‐ quirements” and “Starting up and working with the machine” sections in the VDMA (German Engineering Federation) brochure “Safety manual for concrete delivery and placing machines”. Here you will find a summary of the most important safety regulations. This chapter is therefore particularly useful for providing initial and ba‐...
  • Page 20 2 — 2 Operating Instructions 210110691_2018-09-19_EN...

  • Page 21: Safety Regulations

    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 placing machines are defined as: ●...

  • Page 22: Truck Mixer

    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 de‐ fined as self-contained pipes or hoses in which concrete is pumped from the concrete pump to the placement site.

  • Page 23: Signaller And Other Auxiliary Personnel

    Safety regulations 2.1.13 Signaller and other auxiliary personnel Persons instructed by the site management to help the machine oper‐ ator in his work if the latter is unable to observe all areas of operation and danger zones. Signallers must be able to independently evaluate all dangerous situations which may occur when working with a con‐...

  • Page 24: Place Of Work, Working Area, Danger Zone

    Safety regulations 2.1.19 Place of work, working area, danger zone 2.1.19.1 Mobile machines Figure 1: Example 2.1.19.2 Stationary machines Figure 2: Example 2 — 6 Operating Instructions 210110691_2018-09-19_EN...
  • Page 25 Safety regulations Pos. Designation Explanation Place of work (during Machine operator In normal operation, with the remote con‐ pumping operations) trol Hoseman At the end hose in the danger zone Signaller In the machine operator's range of vision Auxiliary personnel As machine operators of the manual placing system Truck mixer driver...
  • Page 26 Safety regulations 2.1.19.3 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 – machine operator The machine operator's place of work is with the remote control when the pump is in operation.
  • Page 27 Safety regulations Impermissible working area Because of their high manoeuvrability, some placing booms can also be shifted into positions for which they are not designed. This may overload or damage the placing boom. Placing booms must therefore (Impermissible only be moved within the permitted working area. working area P.

  • Page 28: Designated Use

    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 29: Retesting (Safety Inspection)

    Safety regulations You must also observe the Operating Instructions and comply with the intervals and conditions for inspections (particularly retesting) and maintenance work in order to operate the machine within the limits of its proper use. 2.2.1 Retesting (safety inspection) After initial commissioning of the machine, the operational safety of the machine must be checked regularly by a subject expert.

  • Page 30: Improper Use

    Safety regulations The day of initial commissioning in accordance with the handover re‐ port and the machine's operating hours meter are definitive for the in‐ tervals. This operating hours meter records the hours of pumping op‐ erations. The operating hours meter must always be kept in good working order.

  • Page 31: Lifting Loads

    Safety regulations 2.3.2 Lifting loads The placing boom must never be used for lifting loads. 2.3.3 Removing obstacles The placing boom must not be used under any circumstances to re‐ move obstacles. This would overload the placing boom, causing dam‐ age and endangering people.

  • Page 32: Impermissible End Hose

    Safety regulations 2.3.6 Impermissible end hose There must be no couplings, spouts, discharge stops or other items fixed to the outlet end of the end hose unless they are approved by the manufacturer. 2.3.7 Impermissible working area During pumping operations, the end hose must not be moved back‐ wards beyond the vertical axis of rotation of the placing boom.

  • Page 33: Climbing The Placing Boom

    Safety regulations In addition to this, additional impermissible working areas exist, de‐ pending on the machine model and manufacturer, which are descri‐ bed in the Operating Instructions. 2.3.8 Climbing the placing boom It is prohibited to climb the placing boom, to stand on top of it or to misuse it as a working platform or climbing aid.

  • Page 34: Exclusion Of Liability

    Safety regulations Exclusion of liability Where the manufacturer's delivery conditions are agreed, liability will be as described in the provisions there. The manufacturer is not liable for damage in cases specified there. Unless the responsibility of the manufacturer, the warranty will be in‐ validated in the following situations in particular: ●...

  • Page 35: Qualifications

    Safety regulations ● They must have demonstrated their competence to the operator. ● They can be expected to reliably execute the tasks with which they are charged. The operating personnel must not wear loose garments or jewellery, including rings. Long hair which is not tied back must be covered by a hair net.

  • Page 36: Operating Procedures

    Safety regulations As the operator, you must always make sure that the Operating In‐ structions are available. The Operating Instructions and check book must always be kept to hand at the site of use of the machine (in the tool compartment or container provided for this purpose). As the operator, you must have personnel working on the machine confirm in writing their knowledge, understanding and application of the Operating Instructions and Safety Regulations and Safety Man‐...

  • Page 37: Other Regulations

    Safety regulations 2.6.3 Other regulations The current regulations for concrete delivery and placing machines as issued by: ● The legal authorities in your country ● The national supervisory bodies ● The responsible commercial liability insurance company. Personal protective equipment In order to reduce risks to personnel, the operating personnel must use personal protective equipment insofar as this is necessary or deemed to be so by regulations.
  • Page 38 Safety regulations Symbol Meaning Hearing protectors Hearing protectors protect your ears when in the vicinity of the machine against any noise that arises there. (DIN EN 3521; Hearing protectors - General requirements - Part 1: Earmuffs or DIN EN 352-3; Hearing protectors - General requirements - Part 3: Earmuffs attached to industrial safety helmets) Protective gloves...

  • Page 39: Before Working With The Machine

    Safety regulations Symbol Meaning Safety harness When working at height, use the climbing aids and working platforms provided for reasons of safety or wear a safety harness. The relevant national regulations must be complied with. (DIN EN 361; Personal protective equipment against falls from a height - Full body har‐...

  • Page 40: Danger Due To High Voltage

    Safety regulations Set all the control and monitoring devices to the zero position before you change the mode of control (control block, control console or re‐ mote control). Never put the remote control down when the machine is ready for op‐ eration.

  • Page 41: High-Voltage Lines

    Safety regulations Rated voltage [V] Minimum clearance [m] up to 1 kV 1 kV up to 110 kV 110 kV up to 220 kV 220 kV up to 380 kV unknown rated voltage The specified clearances are minimum requirements. You must ob‐ serve any greater clearances that may be specified in the country of use.

  • Page 42: Highvoltage Warning Devices

    Safety regulations 2.9.4 Highvoltage warning devices According to the current rules of engineering, highvoltage warning de‐ vices do not meet a safety standard which enables minimum clearan‐ ces to highvoltage lines that are smaller than the required minimum clearances to be used. Previous experience has shown that highvolt‐ age warning devices cannot make all situations in working proce‐...

  • Page 43: Earthing In The Event Of Electrostatic Charging

    Safety regulations 2.9.6 Earthing in the event of electrostatic charging Working in the vicinity of transmitters (radio transmitter, etc.) can re‐ sult in faults in the radio remote control system and dangerous electri‐ cal charges in the machine. Persons who bridge the charged parts to the earth are heavily charged on contact.

  • Page 44: Stationary Placing Booms

    Safety regulations (Setup site P. 2 — 27) section. Please also observe the 2.10.2 Stationary placing booms Stationary placing booms can be erected on tubular columns, lattice booms or other base structures. The base/structural elements to which the base structure is fixed must be able to withstand the forces and moments transferred via the base structure, as specified in the manufacturer’s information.

  • Page 45: Mobile Machines

    Safety regulations 2.11 Mobile machines 2.11.1 Setup site Site management must prepare and assign the set-up site. It is the machine operator who takes responsibility for setting up the machine safely. The machine operator must inspect the setup site proposed by site management and must refuse to set the machine up at the site of operations if there are any doubts regarding safety.

  • Page 46: Supporting Ground

    Safety regulations 2.11.2 Supporting ground Find out the load-bearing capacity of the supporting ground. The site management will be able to state the permitted ground pressure. If the load-bearing capacity is unknown, assume the that worst case scenario applies. The supporting ground must be level and even. If necessary, set up a level surface on top of the uneven ground.

  • Page 47: Corner Bearing Loads

    Safety regulations 2.11.3 Corner bearing loads The corner bearing load is stated on each support leg. This value must always be legible. The load supported by each support leg is conically diffused in the ground at an angle of 45 °. Safe clearance to the pits and slopes must be maintained, and such clearance must be determined in accord‐...

  • Page 48: Driving

    Safety regulations Do not carry out more than one movement at a time. If a movement is stopped, the entire volume of fluid is available for the remaining movements, and can increase their speeds. Depending on the de‐ sign, it may be the case that carrying out several movements at once (as opposed to carrying out a single movement at maximum speed at any one time) does not bring any advantage in terms of time.
  • Page 49 Safety regulations ● Accessories and moving parts belonging to the machine must be safely stowed/secured. ● The maximum permissible gross weight must not be exceeded. While the vehicle is being driven, the delivery line, pump and hopper must be empty. If there is concrete residue in the hopper, there is a risk of injury from the concrete residue, which may be thrown out while the vehicle is in motion.

  • Page 50: Towing

    Safety regulations For truck mixer concrete pumps, only turn the mixer drum at the maxi‐ mum specified speed of rotation whilst the truck is in motion. The truck is at risk of toppling over, particularly when travelling round cor‐ ners. 2.11.6 Towing The machine must only be towed, loaded and transported in accord‐...

  • Page 51: Placing Booms

    Safety regulations 2.12 Placing booms 2.12.1 Unfold placing boom Only raise a mobile placing boom from the driving position once the machine has been supported in accordance with the Operating In‐ structions. Stationary placing booms may only be raised after the proper set-up has been checked by a subject expert.

  • Page 52: End Hose

    Safety regulations Press the EMERGENCY STOP immediately if the placing BUTTON boom moves unexpectedly. If this should occur, you must cease working and have the cause of the fault rectified by your qualified per‐ sonnel or our After Sales Service personnel. Placing booms with placing boom hinges which allow considerable flex angles have a very large potential working area.

  • Page 53: Guiding The End Hose Ergonomically

    Safety regulations The diameter of the danger zone is twice the end hose length. Do not guide the end hose when pumping is started. There is a risk of acci‐ dent from the end hose swinging out or stones being ejected. (Ex‐...

  • Page 54: Connecting Drills

    Safety regulations 2.12.4 Connecting drills If a drill is connected to the delivery line for the placing boom, it must not place any further strain on the placing boom. The placing boom must be connected to the drill in such a way that the placing boom does not require adjustment.

  • Page 55: Concreting In Cold Weather

    Safety regulations 2.12.6 Concreting in cold weather Placing booms must not be used at temperatures of below minus 15 °C (+5 °F) except with the express approval of the manufacturer. There is a danger of damage to the steel (brittle fracture) and the seals throughout the system at such extreme minus temperatures.

  • Page 56: Leak Tightness And Blockages

    Safety regulations 2.13.3 Leak tightness and blockages Regularly force water through the delivery line under operating pres‐ sure to check that the system is watertight. A properly cleaned delivery line is the best insurance against the for‐ mation of blockages. Blockages increase the risk of accidents. Never attempt to push through a blockage (e.g.

  • Page 57: Opening Delivery Lines

    Safety regulations 2.13.4 Opening delivery lines Delivery lines must not be opened or tapped off while they are pres‐ surised. Concrete exiting under pressure can cause injury. The con‐ crete column must be depressurised by reverse pumping before the delivery line is opened. Never bend over the coupling when you are working.

  • Page 58: Devices For Shutting Off, Diverting And Cleaning

    Safety regulations 2.13.8 Devices for shutting off, diverting and cleaning During operation, there is a risk of being crushed and of injury by shearing. Hydraulically driven devices are generally supplied with power by the hydraulic system of a machine. For this reason, there must always be a line of sight between the devices and the machine fitted with the control unit.

  • Page 59: Remote Control

    Safety regulations 2.14.3 Remote control You must always carry the remote control on your person when the machine is ready for operation. Only in this way can it be guaranteed that you can press the EMERGENCY STOP in the event of an BUTTON emergency situation.

  • Page 60: Constant Observation Of The Machine

    Safety regulations Do not insert any objects (shovel handle, trowel, etc.) into moving ma‐ chine components. Such objects could become trapped and dragged into the machine. They might then hit you or be torn from your hands and cause you injury. 2.14.5 Constant observation of the machine You should be constantly observing the machine for any damage or...

  • Page 61: Cleaning Agents

    Safety regulations The preferred methods for cleaning the delivery line are reverse pumping or forced cleaning with water. The agitator must be switched on during reverse pumping. Otherwise, the concrete flowing back into the hopper can bend the agitator shaft. Use a catch basket, pipe cleaning head and wash-out ball for forced cleaning to prevent any water from flowing into the formwork.

  • Page 62: Cleaning With Compressed Air

    Safety regulations manufacturer's instructions regarding use and safe handling. Wear protective clothing. Always rinse off cleaning agent thoroughly with clean water; do not allow puddles to form. Do not use sea water or other water containing salt for cleaning pur‐ poses.

  • Page 63: Protection Against Water

    Safety regulations ● A catch basket must be fastened at the end of the delivery line and a wash-out adaptor must be fitted on the head of the delivery line. The catch basket and washout adaptor must fit the delivery line system.

  • Page 64: Post-Cleaning Procedure

    Safety regulations You must close/seal all openings into which water/steam/cleaning agent must not penetrate for safety or functional reasons before cleaning the machine with water or a steam jet (high-pressure clean‐ er) or other cleaning agents. Electric motors and control cabinets are particularly at risk.
  • Page 65 General technical description This chapter describes the components and assemblies on this ma‐ chine and describes how they function. Please note that possible (op‐ tional) additional equipment is also described. Refer to the machine card to check whether you have the particular additional equipment or not.
  • Page 66 3 — 2 Operating Instructions 210110691_2018-09-19_EN...

  • Page 67: General Technical Description

    General technical description Overview Below you will find an overview of the most important components; these will then be described on the following pages. Figure 3: Structure of the left-hand side of the truck Item Designation Documentation accompanying the machine Remote control: (Remote control P.
  • Page 68 General technical description Item Designation Agitator safety cutout on the hopper (installation location on the hopper varies): (Agitator safety cutout (RSA) P. 3 — 134) Transfer tube: (Assembly not present) Folding rear lights (underride protection optional): (Folding rear lights P. 3 — 165) Vibrator (on the grille): (Vibrator P.

  • Page 69: Technical Data

    General technical description Item Designation Magnetic switch distributor casing: (Magnetic switch distributor casing P. 3 — 131) Hydraulic fluid radiator: (Hydraulic fluid radiator P. 3 — 161) Compressor (optional): (Assembly not present) Emergency operation of the compressor: (Assembly not present) Microfilter (optional): (Assembly not present) Right-hand support control block:...

  • Page 70: Machine Rating Plate

    General technical description P131383 The machine can be used in residential areas without restriction. 3.2.2 Machine rating plate Figure 5: Machine rating plate Item Designation Manufacturer's address Designation of the machine Machine model Machine number Maximum fluid pressure in the hydraulic system [bar] Gross weight [kg] marking.
  • Page 71 General technical description If specific details do not apply to a machine, the relevant fields are blank. With truck-mounted concrete pumps, the weight specified by the truck manufacturer applies as per Regulation EU 19/2011 “Official‐ ly permitted gross weight specified by manufacturer”. 3.2.3 Placing boom rating plate Figure 6: Placing boom rating plate...
  • Page 72 General technical description Item Designation Item Designation Year of manufacture Max. horizontal reach Max. vertical reach Max. end hose Hydraulic pressure max. Max. delivery pressure Data for the delivery line on the placing boom Item Designation MN (material number) DN (nominal diameter) Model (maximum permitted outside diameter and wall thickness of the delivery line) Coupling type (AL = aluminium, ST = steel)

  • Page 73: Sound Pressure Level/Sound Power Level

    General technical description Item Designation Pump delivery line data Item Designation MN (material number) DN (nominal diameter) Model (maximum permitted outside diameter and wall thickness of the delivery line) V1 - V10: Pump - riser pipe adapter pipe lengths 3.2.4 Sound pressure level/sound power level CAUTION Damage to health caused by noise emissions...
  • Page 74 General technical description Close to the machine's rating plate, you will find the plate that is shown below, which specifies the guaranteed sound power level of the machine. Figure 7: Sound power level 3.2.4.3 What does this mean? A uniform method of measuring the “noise” generated by a machine (Directive 2000/14/EC) has been applicable throughout Europe since 3rd January 2002.
  • Page 75 General technical description power level, the calculated sound pressure level is now multiplied by the surface area of the imaginary sphere. The sound power level is given in dB. Advantage: If you now move closer to the machine, the sound pres‐ sure level is, of course, greater.

  • Page 76: Reaches

    General technical description 3.2.5 Reaches The placing boom has the horizontal reach listed below. Figure 8: Reach diagram Item Designation Horizontal reach from middle of slewing unit: 41.1 m Horizontal reach from front edge of truck: 38 m Vertical reach: 46.1 m Unfolding height: 11.1 m Depth of reach with 3 m end hose: 32.4 m 3 —...

  • Page 77: Definition Of Working Areas

    General technical description Angle of rotation of the hinges Designation Value A hinge (from boom cradle) +90 °/-4,5 ° B hinge 180 ° C hinge 180 ° D hinge 235 ° E hinge 230 ° 3.2.6 Definition of working areas WARNING Risk of death The machine can topple over if you move the placing boom outside...
  • Page 78 General technical description Figure 9: Example illustration with limited support “R” Item Designation Extended working area: Move placing boom with Arm 1 positioned ver‐ tically with restricted horizontal reach. The remaining arms can be moved when extended. Working area: Any placing boom position 3 —...
  • Page 79 General technical description 3.2.6.1 Impermissible working area The impermissible working area is the area behind the vertical line of the placing boom. You may move the arms of the placing boom in this area. You may not move the end hose in this area. Figure 10: Overview of the impermissible working range Item Designation...
  • Page 80 General technical description 3.2.6.2 Minimised load position (LMS) In the minimised load position, you can move the placing boom out of the permissible working area without compromising the stability of the machine as a result. In the minimised load position, Arm 1 is vertical and all other arms are folded.

  • Page 81: Support Variants

    General technical description 3.2.7 Support variants WARNING Risk of death If the machine is set up with limited support and the support moni‐ toring is defective, you will be able to move the placing boom out of the working area. The machine may topple over. 1.
  • Page 82 General technical description Figure 12: Support widths Item Designation 1.2 m 2.8 m 4.5 m 1.7 m 2.2 m The working areas of the machine are shown in the Operating In‐ structions as follows: Illustration Working area Permissible working area Extended working area 3 —...
  • Page 83 General technical description “S” standard 360° 360° forward support legs Both: Telescoped to end position, support feet lowered rear support legs Both: Swung out to end position, support feet lowered “RF” right frontal -3° - 200° 360° forward support legs Left: Telescoped to end position, support foot lowered Right: Telescoped to end position, support foot lowered rear support legs...
  • Page 84 General technical description “R1” right – intermediate position 1 -3° - 140° -3° - 200° forward support legs Left: Telescoped to intermediate position 1, support foot lowered Right: Telescoped to end position, support foot lowered rear support legs Left: Swung out by > 1 m to flatbed, support foot lowered Right: Swung out to end position, support foot lowered “R1s ”...
  • Page 85 General technical description “Rs” right narrow 10° - 130° -3° - 130° forward support legs Left: Not telescoped, support foot lowered Right: Telescoped to end position, support foot lowered rear support legs Left: Swung out by > 0.25 m to flatbed, support foot lowered Right: Swung out to end position, support foot lowered “Fs”...
  • Page 86 General technical description “F1s” frontal support – narrow intermediate position 1 0° 140° - 220° forward support legs Both: Telescoped to intermediate position 1, support feet lowered rear support legs Both: Swung out > 0.25 m, support feet lowered “D” Driving / “0” Cleaning forward support legs Both: Not telescoped, support feet not lowered rear support legs...
  • Page 87 General technical description 3.2.7.2 Limited support The machine has limited support when support variants are used in which the support legs are only partially extended. Limited support is used on construction sites where space is restricted. 3.2.7.3 F support WARNING Risk of death The machine can topple over if concrete is distributed over the hop‐...

  • Page 88: Description Of The Functions

    Delivery line Delivery lines and risers consist of straight pipe sections and delivery line bends. These can be easily interchanged. Standard Putzmeister delivery line couplings are used as pivot hinges and pipe connectors. The pipe elbow hinge at the end of the boom acts as a concrete brake and reduces wear on the end hose.

  • Page 89: Hydraulic Boom Control

    Transfer tube Hinged elbow on the pressure connection Putzmeister pumps are driven hydraulically via oil pumps by diesel engines or electric motors. The delivery pistons are connected hy‐ draulically with each other via drive cylinders. They operate in a push- 3 —...

  • Page 90: Combination Lubrication

    General technical description pull mode. The returning delivery piston sucks the medium in. At the same time, the advancing delivery piston pushes the medium previ‐ ously sucked in via the hinged elbow or the pressure connection into the delivery line. The pump switches over at the end of the stroke. The transfer tube swings in front of the filled delivery cylinder and the delivery pistons reverse their direction of movement.

  • Page 91: Service Life

    3.4.3 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 92: Electrical Control Devices

    General technical description Electrical control devices The electrical control devices and operating elements on this machine are described on the following pages. The overview at the start of this chapter will show you where the individual control devices are located on the machine.

  • Page 93: Colour Definition - Leds In The Button

    General technical description 3.5.1 Colour definition – LEDs in the button Each on the operating panels of this machine has four integra‐ BUTTON ted LEDs that indicate the status of a function as follows: Figure 14: Example illustration: Switch support leg monitoring on/off button Item Designation Red LED...
  • Page 94 General technical description WARNING Risk of injury ▶ Firmly hold the cover of the stowage compartment so that it is secure while opening the stowage compartment. Figure 15: Setup of the central control cabinet Item Designation Control panel on the central control cabinet Diagnostics socket Locally latched toggle switch with the following switch positions: “Local control”...
  • Page 95 General technical description Button Description Support leg warning lights On/Off Spotlights for lighting the support areas On/Off (Optional) Spotlight on placing boom On/Off (Optional) Lower fill-level sensor override On/Off Table 1: Control panel on the central control cabinet 3.5.2.1 Locking the central control cabinet The central control cabinet is located in a stowage compartment.

  • Page 96: Support Monitoring

    General technical description 3.5.2.4 Switchover from local to remote control The EMERGENCY STOP is activated automatically when you switch over between local and remote control. To deactivate the EMERGEN‐ CY STOP, you must press the “Deactivate EMERGENCY STOP” BUT‐ on the remote control or on the control panel by the steps. 3.5.2.5 Fill-level monitor (optional) There are two fill-level sensors in the hopper.
  • Page 97 This locks the areas near to and above the driver’s cab for the placing boom. Depending on the equipment fitted, you can have the locked areas reconfigured by the Putzmeister After Sales department in order to protect retrofitted components (e. g. flashing beacons). 3.5.3.1 Red flashing light The red flashing light is fitted on both sides above the stowage com‐...
  • Page 98 General technical description Figure 16: Position of the red flashing light 3.5.3.2 Process monitoring mode 1 If you have to set up the machine on a gradient, thereby exceeding the maximum permissible gradient, you can switch on “Process moni‐ toring mode 1”. WARNING Risk of death The machine may topple over.
  • Page 99 General technical description WARNING Risk of death In “Process monitoring mode 1”, you can move the placing boom in‐ to an unsafe area. The machine may topple over. You can reduce the risk by following the instructions below. 1. Only move the placing boom slowly when approaching the lim‐ its of the working area in “Process monitoring mode 1”.
  • Page 100 General technical description WARNING Risk of death Components may become overloaded if the machine is at a gradi‐ ent of more than 3°. 1. Support the machine at a maximum lateral gradient of 3°. 2. Unfold the placing boom lengthwise to the gradient (uphill/ downhill) if the longitudinal gradient of the machine is greater than 3°.
  • Page 101 General technical description In “Process monitoring mode 1”, a warning is displayed on the screen of the remote control, depending on the machine model. In “Process monitoring mode 1”, the raise monitoring and gradient monitoring are deactivated. Raise the machine to achieve the maximum possible stability. The unladen weight of the machine acts as ballast.
  • Page 102 General technical description Only use “Process monitoring mode 1” if, because of local conditions, you cannot maintain the gradient or ensure that the machine is fully raised. The “Process monitoring mode 1” functions as follows: ● The support monitoring system is active. The safety system de‐ tects which support variant has been selected and enables the working area or extended working area.
  • Page 103 General technical description Central control cabinet Figure 18: Setup of the central control cabinet Item Designation Control panel on the central control cabinet Diagnostics socket Locally latched toggle switch with the following switch positions: “Local control” “0” “Remote control” “Process monitoring mode On − Off” keyswitch (Support monitoring P.
  • Page 104 The countdown is displayed on the screen of the remote control. During this period, you must have the fault rectified by a Putzmeister service technician. Once support monitoring is working correctly, the time is reset.

  • Page 105: Control Panel By The Steps

    General technical description 3.5.4 Control panel by the steps The control panel is located on the right-hand side of the truck near to the hopper. Some of the control and operating elements illustrated below may not be present on your machine. Functions such as agitator, high-pressure water pump and flushing water pump are mutually locked.
  • Page 106 General technical description 3.5.4.1 Control panel operating panel by the steps Figure 20: Control panel operating panel – Upper row Item Designation Button “Deactivate EMERGENCY STOP” Button “Forward pumping (in local operation) On/Off” Button “Agitator (in local operation) On/Off – for forward pumping” Button “Fill water box On/Off”...
  • Page 107 General technical description Figure 21: Control panel operating panel – Middle row Item Designation Button “Acknowledge agitator safety cutout” Button “Reverse pumping (in local operation) On/Off” Button “Agitator (in local operation) On/Off – for reverse pumping” Button “Central lubrication pump (in local operation)” Start manual lubrication cycle Button “High-pressure water pump On/Off”...
  • Page 108 General technical description Figure 22: Control panel operating panel – Lower row Item Designation Button “Horn On/Off” Button “Pump Off” Button “Working light on hopper On/Off” Button “Vibrator On/Off” Button “Working light in pump area On/Off” and (optional) “Working light on Arm 1 On/Off”...
  • Page 109 General technical description Pressing the “Forward pumping (in local operation) On/Off” BUTTON once switches the forward pumping on. ● The yellow LED lights up when you press the BUTTON ● As soon as the forward movement has been started, the green LED lights up.
  • Page 110 General technical description Pressing the “Fill water box On/Off” again closes the water BUTTON supply valve. ● The yellow and green LEDs light up simultaneously when you press the BUTTON ● The yellow and green LEDs go out when the water supply to the water box is switched off.
  • Page 111 General technical description Pressing the “Reverse pumping (in local operation) On/Off” BUTTON once switches the reverse pumping on. ● The yellow LED lights up when you press the BUTTON ● As soon as the reverse movement has been started, the green LED lights up.
  • Page 112 General technical description Pressing the “Centralised lubrication system pump (in local operation) On/Off” once in local operation starts the manual lubrication BUTTON cycle for the pump. ● The yellow LED lights up when you press the BUTTON ● The green LED lights up during the lubrication procedure. The lu‐ brication procedure automatically stops once the lubrication is complete.
  • Page 113 General technical description Pressing the “Pump Off” once stops the pump. BUTTON ● The yellow LED lights up when you press the BUTTON ● When the pump has been switched off, the green LEDs in the “Forward pumping (in local operation) On/Off” and “Reverse pump‐ ing (in local operation) On/Off”...
  • Page 114 General technical description Button “Working light in pump area On/Off” Pressing the “Working light in pump area On/Off” once BUTTON switches on the working light in the pump area. Pressing this BUTTON may also switch the spotlight on Arm 1 on/off. ●...

  • Page 115: Remote Control

    General technical description Water pumps/agitator The water pumps and the agitator cannot operate at the same time. The yellow LED on the “Switch on highpressure water pump” BUT‐ flashes when highpressure water pump's dryrunning protection function is activated. 3.5.5 Remote control You can control the machine using the remote control.
  • Page 116 General technical description 3.5.5.1 Radio base station Figure 24: Organisation of the radio base station Item Designation Indicator lights “Display operating states” “Remote control connection” socket “Central module control cabinet connection” socket The indicator lights are described in the manufacturer's Operating In‐ structions for the radio base station.
  • Page 117 General technical description 3.5.5.2 Front view of the remote control Figure 25: Organisation of the remote control Item Designation Joystick “boom control” Button “Operation of the screen” ergonic 2 screen with menu-oriented displays and adjustable functions Button “Increase/reduce engine speed” Button “Engine On/Off”...
  • Page 118 General technical description Switch po‐ Symbol Description sition Support leg control “Zero” ● No operating mode selected Single-axis regulated driving (EBC) ● Move individual arms with boom damping ● Self-collision is taken into account ● Working range limits are taken into account Coupled driving (EBC) ●...
  • Page 119 STOP button, the EMERGENCY STOP function is triggered 3.5.5.4 STOP button Putzmeister remote controls include a STOP button that has the same function as the EMERGENCY STOP button on the machine. This is a requirement under the European standard DIN EN 60204-1:2014-10.
  • Page 120 General technical description 3.5.5.6 Joysticks WARNING Risk of injury from unintended movement of the placing boom Simultaneous operation of the and a OPERATING MODE SELECTOR SWITCH can cause unintended boom movements, which could lead JOYSTICK to serious injuries. ▶ Only operate the after you have OPERATING MODE SELECTOR SWITCH released the...
  • Page 121 General technical description Symbol Function/meaning Green: Raise second-to-last arm Green: Lower second-to-last arm Green: Raise third-to-last arm Green: Lower third-to-last arm Righthand joystick The first two arms and slewing gear are moved using the right-hand joystick. Symbol Function/meaning Black: Raise Arm 1 Red: Retract the end hose completely Black: Lower Arm 1 Red: Move the end hose fully forwards...
  • Page 122 General technical description Symbol Function/meaning Green: Raise Arm 3 (only on placing booms with six arms) Black: Raise Arm 2 Red: Raise the end hose completely Green: Lower Arm 3 (only on placing booms with six arms) Black: Lower Arm 2 Red: Lower the end hose completely Turn the slewing gear to the left Turn the slewing gear to the right...

  • Page 123: Remote Control Display

    General technical description 3.5.5.9 Additional aerials If you fit additional aerials (e.g. radio, telephone), you must maintain a minimum clearance of 1 m between those aerials and the aerial for the remote control, because otherwise faults may occur in the remote control system.
  • Page 124 General technical description Additional functions EBC Basis Moving the end hose (“Coupled driving” oper‐ ating mode) Unfolding aid for the placing boom Specifying speeds for individual arms Boom damping Folding assistance with automatic lowering of the placing boom EBC Plus All EBC Basis functions Specifying placing boom speeds for directions (vertical, horizontal, slewing)
  • Page 125 General technical description 3.5.6.2 Screen and operating elements Figure 27: Operating elements Item Designation Display - Menudriven displays and adjustable functions are shown here. Buttons - Function buttons F1, F2, F3, F4, F5 and F6 for navigation and operation. General status information for the remote control is displayed at the upper edge of the display.
  • Page 126 General technical description Figure 28: Screen areas Item Designation Information area: Menudriven operating states, displays and faults are shown in the infor‐ mation area. Interaction area: Symbols for the function of the function buttons (e.g. opening a menu, switching a function on/off) Status line 3.5.6.3 Status line...
  • Page 127 General technical description 3.5.6.4 Menu structure In order to improve clarity, the menu structure is divided into menu sections below, taking the “HOME” menu as an example and using the “Menu navigation”. When the machine is started up, “HOME” is always shown as the start screen.
  • Page 128 General technical description Function Symbol Description button Switch EOC on/off (Ergonic Output Control P. B — 17) “Support” menu (“Support” menu P. 3 — 67) “Boom settings” menu (“Boom settings” menu P. 3 — 72) “Pump status” menu (“Pump status” menu P. 3 — 85) 3.5.6.5 “Menu navigation”...
  • Page 129 General technical description Function Symbol Description button Open last menu opened Navigate left on the menu ribbon “Machine information” menu (“Machine information” menu P. 3 — 103) “Home” menu (“HOME” menu structure P. 3 — 63) Navigate right on the menu ribbon Open selected menu Menu ribbon Depending on the initial menu, the following menus can be displayed.
  • Page 130 General technical description Menu symbol Menu name Boom settings Boom speed Cleaning Limit setting Upper and lower limit setting Limit individual arms and slewing gear Agitator Additional functions 1 Status messages Fault messages 3 — 66 Operating Instructions 210110691_2018-09-19_EN...
  • Page 131 General technical description Example of menu selection: Select “Cleaning” menu The menu highlighted in yellow in the centre can be selected. Figure 29: Select “Cleaning” menu Item Designation Menu ribbon and menu navigation Pressing F5 in the “Menu navigation” menu brings the “Cleaning” menu into the menu selection.
  • Page 132 General technical description The status of the “Support monitoring” safety system is displayed in the “Support” menu: ● Status of the support legs ● Support variant (resulting from the status of the support legs) ● Working area ● Spirit level display ●...
  • Page 133 General technical description Function Symbol Description button “Spirit level” menu (“Spirit level” menu P. 3 — 70) “Boom settings” menu (“Boom settings” menu P. 3 — 72) “Pump status” menu (“Pump status” menu P. 3 — 85) Status dis‐ Description play Countdown clock: 40 operating hours The number of remaining operating hours is dis‐...
  • Page 134 General technical description Colour Definition No colour The support leg is not extended. Blue The support leg is in a valid intermediate position. Green The support leg is fully extended. Yellow Support leg position is not defined (support leg not in support position or snaplock not locked). Support sensor fault “Spirit level”...
  • Page 135 General technical description Function Symbol Description button “Support” menu (“Support” menu P. 3 — 67) “Boom settings” menu (“Boom settings” menu P. 3 — 72) Pump status menu (“Pump status” menu P. 3 — 85) Status dis‐ Description play Number of remaining support attempts Number and monitoring status of truck axles Position of the machine: The position of the spirit level corresponds to the position of the machine dis‐...
  • Page 136 General technical description Raising the truck axles – colour definitions The following status information is displayed in the “Spirit level” menu during the machine's support operation: ● Number of truck axles ● Raising of the truck axles (displayed in colour) The colours have the following meanings: Colour Definition...
  • Page 137 General technical description Function Symbol Description button Lubricate placing boom once “Set limits” menu (“Set limits” menu P. 3 — 73) Red lock: Limits set Green lock: No limits set “Select boom speed” menu (“Select boom speed” menu P. 3 — 79) 3.5.6.8 “Set limits”...
  • Page 138 General technical description The limits set are then only monitored if the OPERATING MODE SELEC‐ is moved to switch position 3 “Single axis regulated driv‐ TOR SWITCH ing ”or to switch position 4 “Coupled driving”. The “Set limits” menu and the associated functions can also be used to a limited extent without the EBC function.
  • Page 139 General technical description Function Symbol Description button “Upper and lower limit setting” menu (EBC Plus) (“Upper and lower limit setting” menu (EBC Plus) P. 3 — 75) Red lock: Limits set Green lock: No limits set Delete all limits set in this menu “Limit individual arms and slewing gear”...
  • Page 140 General technical description NOTICE Collision with obstacles can damage the machine ▶ Keep an eye on the placing boom at all times during semi-auto‐ matic operation. The limits set are then only monitored if the OPERATING MODE SELEC‐ is moved to switch position 3 “Single axis regulated driv‐ TOR SWITCH ing ”or to switch position 4 “Coupled driving”.
  • Page 141 General technical description 3.5.6.10 “Limit individual arms and slewing gear” menu When in operating mode 6 “Single-axis unregulated driving”, the “Lim‐ it individual arms and slewing gear” menu can be used to lock individ‐ ual axles (slewing gear and arms) – this means that the individual arm can no longer be moved.
  • Page 142 General technical description Function Symbol Description button Select slewing gear or arm Lock the selected arm Delete all limits set in this menu Set upper limit for the selected arm Set lower limit for the selected arm “Slewing gear and limited arms” selection area – colour definitions In the “Limit individual arms and slewing gear”...
  • Page 143 General technical description If a limit is set in the selected field, the colour of the field changes to red and continues flashing until F2 is pressed and the next field is se‐ lected as a result. 3.5.6.11 “Select boom speed” menu WARNING Risk of injury from unintended movement of the placing boom Simultaneous operation of the...
  • Page 144 General technical description Figure 30: Organisation of the operating mode selector switch Item Designation Switch position 1: “Support leg control” Switch position 2: “0” or switch position when the remote control is switched on Switch position 3: “Single axis regulated driving” Switch position 4: “Coupled driving”...
  • Page 145 General technical description Function Symbol Description button “User-defined boom speed for single-ax‐ is operation” menu (“User-defined boom speed for single-ax‐ is operation” menu P. 3 — 82) “User-defined boom speed for coupled operation (EBC Plus)” menu (“User-defined boom speed for coupled operation (EBC Plus)”...
  • Page 146 General technical description Status dis‐ Symbol Description play Boom The “slow” boom speed is activated speed The “fast” boom speed is activated The “user-defined” boom speed is activa‐ 3.5.6.12 “User-defined boom speed for single-axis operation” menu You can set the speeds for the individual axes of the placing boom in the “User-defined boom speed for single-axis operation”...
  • Page 147 General technical description Function Symbol Description button Select axis Reduce the speed of the selected axis Reset the speed of the selected axis to the standard value Save setting Increase the speed of the selected axis 3.5.6.13 “User-defined boom speed for coupled operation (EBC Plus)” menu You can set and store the speeds for the directions of movement of the end hose in the “User-defined boom speed for coupled operation”...
  • Page 148 General technical description Function Symbol Description button Select axis Reduce the speed of the selected axis Reset the speed of the selected axis to the standard value Save setting Increase the speed of the selected axis Status dis‐ Symbol Description play Selected di‐...
  • Page 149 General technical description 3.5.6.14 “Pump status” menu The “Pump status” menu is used to operate the machine during pumping. The “Pump status” menu acts as the main menu for opera‐ tion. A number of submenus can be navigated to from the menu. The symbols and functions in the menus and submenus are described in the following section.
  • Page 150 General technical description Status dis‐ Description play Current delivery pressure Current output Current hydraulic fluid temperature Current engine speed 3.5.6.15 “Pump info” menu There are digital and analogue displays for the delivery pressure and output in the “Pump info” menu. There are also digital displays for the hydraulic fluid temperature and the engine speed, as in the “Pump status”...
  • Page 151 General technical description Function Symbol Description button Lubricate core pump once (“Limit de‐ “Limit delivery pressure” menu livery pressure” menu P. 3 — 88) (“Limit output” menu “Limit output” menu P. 3 — 89) (“Limit delivery “Limit delivery rate” menu rate”...
  • Page 152 4. Use only delivery lines, delivery line elements and hose lines that have been approved by Putzmeister. 5. Wear personal protective equipment. The delivery pressure limit is an auxiliary function that reduces the risk of blockages, minimises energy consumption and wear and pre‐...
  • Page 153 General technical description Function Symbol Description button Switch delivery pressure limit on/off Reduce the limit for the delivery pressure Reset the limit for the delivery pressure to the last saved value Save Increase the limit for the delivery pres‐ sure Status dis‐...
  • Page 154 General technical description If you switch off the ignition, the following will happen: ● The limit for the output will be set to 100%. ● The set limit for the output will not be saved. The following values are displayed from left to right under the bar chart: ●...
  • Page 155 General technical description Status dis‐ Description play Output 3.5.6.18 “Limit delivery rate” menu The same delivery rate can be pumped multiple times consecutively. The pumping process is stopped once the preset delivery rate has been pumped. The following values are displayed from bottom to top alongside the bar chart: ●...
  • Page 156 General technical description Function Symbol Description button Switch delivery rate restriction on/off “Set delivery rate limit” menu (“Set delivery rate limit” menu P. 3 — 94) Status dis‐ Description play Delivery rate The bar shows the following colours: Colour Definition Green Pumped delivery rate Blue...
  • Page 157 General technical description After restarting the set delivery rate and the core pump, the delivery rate that has been pumped is reset to “0”. The pumping process can be interrupted at any time. If the machine enters a special state during a period of limited pump‐ ing, this has the following consequences: State Result...
  • Page 158 General technical description Delivery rate too high Stop the core pump if the required delivery rate has been reached but the core pump does not stop automatically. Pressing F2 will save the currently pumped delivery rate as the new delivery rate limit. “Set delivery rate limit”...
  • Page 159 General technical description Status dis‐ Description play Delivery rate limit Follow this process to set the delivery rate limit: 1. Press F2 until the required digit is selected. 2. Press F3 to reduce the value or press F6 to increase the value. 3.
  • Page 160 General technical description Function Symbol Description button “Smart pump” menu (technology kit) (“Smart pump” menu (technology kit) P. 3 — 97) Switch the hydraulic fluid cooler on/off “Lighting” menu The working lights and signal lights of the machine can be switched on and off in the “Lighting”...
  • Page 161 General technical description Function Symbol Description button Switch the support leg indicator lights on/off Switch the spotlights on the placing boom on/off “Smart pump” menu (technology kit) You can select an optimised default setting for the pumping charac‐ teristics in order to adapt the characteristics of the piston pump to the working conditions in the “Smart pump”...
  • Page 162 General technical description The Smart pump function modes determine parameters that are used for pumping. Smart pump will be deactivated after the ignition and/or power take-off have been switched off. If the engine has been switch‐ ed off or the EMERGENCY STOP state is active, the selected mode is saved.
  • Page 163 General technical description Function Symbol Description button Switch agitator off Switch “Agitator for forward pumping” on Switch “Automatic mode” on Switch “Agitator for reverse pumping” on Status dis‐ Symbol Description play Direction of “Agitator for forward pumping” switched rotation of the agitator “Automatic mode”...
  • Page 164 General technical description Function Symbol Description button Switch flushing water pump on/off Switches the highpressure water pump on/off Switch on/off the compressor (optional) Switch “Agitator for forward pumping” on/off Lubricate core pump once Status dis‐ Description play Combination lubrication active 3.5.6.22 “Lubricate core pump”...
  • Page 165 General technical description Function Symbol Description button Lubricate core pump once High lubricant volume Standard lubricant volume Low lubricant volume Status dis‐ Symbol Description play Selected lu‐ High lubricant volume bricant vol‐ Standard lubricant volume Low lubricant volume Combina‐ Placing boom is being lubricated tion lubrica‐...
  • Page 166 General technical description 3.5.6.23 “Lubricate placing boom” menu (optional) You can start a lubrication cycle for the placing boom and select a lu‐ brication volume in the “Lubricate placing boom” menu. The selected lubricant volume is displayed in the middle of the screen.
  • Page 167 General technical description Status dis‐ Symbol Description play Selected lu‐ High lubricant volume bricant vol‐ Standard lubricant volume Low lubricant volume Combina‐ Core pump is being lubricated tion lubrica‐ tion 3.5.6.24 “Machine information” menu General machine information is displayed in the “Machine informa‐ tion”...
  • Page 168 General technical description Function Symbol Description button “User settings – machine” menu (“User settings – machine” menu P. 3 — 105) “User settings – remote control” menu (“User settings – remote control” menu P. 3 — 106) Status dis‐ Description play Total placing boom operating hours Total core pump operating hours...
  • Page 169 General technical description “User settings – machine” menu In the “User settings – machine” menu, you can define how the water pump can be operated in remote operation mode. You may not operate the water pump using the remote control in local operation.
  • Page 170 General technical description Function Symbol Description button Water pump operating position Remote control Local control “Switch water pump on/off” mushroom- head button (if present) in remote opera‐ tion Available Not available “User settings – remote control” menu In the “User settings – remote control” menu, you can access the me‐ nus in which you can adapt the remote control display to meet your needs.
  • Page 171 General technical description 3.5.6.25 “Switch over units” menu You can switch over between metric and imperial units in the “Switch over units” menu. Function Symbol Description button Select imperial units Select metric units Status dis‐ Symbol Description play Selected Imperial units selected units Metric units selected 3.5.6.26...
  • Page 172 General technical description Figure 31: HBC menu The selected menu item is highlighted. The corresponding symbol is displayed on the right. You can open submenus and adjust and save settings there using the function buttons. The following symbols are assigned to the function buttons: Symbol Description...
  • Page 173 General technical description Symbol Description Change digit Save changes Table 3: Operating the HBC menu You can select the following submenus in the HBC menu. The de‐ scription lists any second-level submenus (where present). Menu Description “Warnings” menu Display remote control fault messages “Information”...
  • Page 174 General technical description Menu Description “Settings” menu “Time” menu Set the time Access to master level (only Putzmeister After Sales department) “Safety” menu The functions of this area can only be accessed by the Putzmeister After Sales department. Main page The HBC menu is closed.
  • Page 175 General technical description Figure 32: “Fault messages” menu Item Designation Navigate horizontally in a line Navigate to the next line Activate emergency strategy You can acknowledge the following fault messages: Symbol Meaning/cause Short-circuited signal outlet in the machine control system. Placing boom hydraulic pressure fault Hydraulic fluid temperature too high/defective sensor...
  • Page 176 General technical description Symbol Meaning/cause Hydraulic fluid low The slewing gear resolver reports a fault. Switch the ignition off and back on again once if you cannot acknowledge the fault. One of the sensors for monitoring the driver's cab is defective. The driver's cab is then no longer monitored and can be damaged by the moving placing boom.
  • Page 177 General technical description Symbol Meaning/cause Fault in the placing boom centralised lubrication system ● Check the grease fill level ● Check the line for blockages ● Check the sensor for the completion of the lu‐ brication procedure Fault in the core pump centralised lubrication sys‐ ●...
  • Page 178 General technical description Figure 33: “Status messages” menu Item Designation Navigate horizontally in a line Navigate to the next line Activate emergency strategy The following table lists the potential status messages and the corre‐ sponding symbols. All of the symbols remain visible as long as the status applies.
  • Page 179 If this indicator still continues to be displayed, you must have the fault rectified by a Putzmeister service technician. Hydraulic fluid low The hydraulic fluid level has dropped below the monitored minimum value.
  • Page 180 General technical description Symbol Meaning/cause Vacuum return flow filter element heavily clogged The condition of the vacuum return flow filter is saved in the control system. The filter element needs to be changed as quickly as possible. The machine operator can continue working for a short period.
  • Page 181 General technical description Symbol Meaning/cause Driver’s cab protection display: The limit has been reached on the right. The placing boom must be moved in the opposite direction. Driver’s cab protection display: The upper limit has been reached. The placing boom must be moved in the opposite direction.
  • Page 182 General technical description Symbol Meaning/cause The placing boom is in the minimised load posi‐ tion and can move over an area between two working areas. The placing boom has stopped because it has reached the set limit. The placing boom can no longer be moved downwards.
  • Page 183 General technical description The following table lists the potential status messages and the corre‐ sponding symbols. All of the symbols remain visible for as long as the status applies. Symbol Meaning/cause This warning appears once “Process monitoring mode 1” is switched on. This warning appears once “Process monitoring mode 2”...
  • Page 184 Machine fail‐ Meaning/cause ure warning symbol Internal fault Have the fault rectified by a Putzmeister service technician. The control cabinet signal outlet has short-circuit‐ Have the fault rectified by a Putzmeister service technician. 3 — 120...
  • Page 185 Meaning/cause ure warning symbol The EMERGENCY STOP button on the remote control is defective. Have the fault rectified by a Putzmeister service technician. The “Local/Remote” switch is defective. Have the fault rectified by a Putzmeister service technician. Remote control system fault The release signal for the placing boom cannot be checked.
  • Page 186 Machine fail‐ Meaning/cause ure warning symbol EMERGENCY STOP system fault Have the fault rectified by a Putzmeister service technician. The grille is open. The agitator safety cutout is ac‐ tivated. The gradient limit has been exceeded: The ma‐ chine has inclined by 0.5°. The warning can be cancelled within the permissible gradient limits (+/-3°);...
  • Page 187 Check the valve connector on the boom control block and the cabling. Fault when determining the forward support leg positions. Have the fault rectified by a Putzmeister service technician. The power take-off for the placing boom is not en‐ gaged.
  • Page 188 General technical description Machine fail‐ Meaning/cause ure warning symbol The power take-off for the core pump is not en‐ gaged. Engage the power take-off for the core pump so that you can use the associated functions. The placing boom is in a minimised load position and can move over an area between two working areas.

  • Page 189: Bracket For Radio Remote Control Transmitter

    General technical description 3.5.7 Bracket for radio remote control transmitter A bracket for the radio remote control transmitter can be found in the driver's cab. If the transmitter is not placed in the bracket, a warning signal sounds when the power take-off is switched to Driving. Figure 36: Bracket structure Item Designation...

  • Page 190: Warning Light On The Support Leg

    General technical description NOTICE Material damage The boom cradle may be damaged if you do not stop the downward movement of the boom as soon as the placing boom is resting on the boom cradle. 1. Follow the sequence for folding the placing boom. 2.

  • Page 191: Spotlights For Lighting The Support Areas

    General technical description You can operate the warning lights on the support legs at the follow‐ ing points if the ignition is switched on and the power take-off is en‐ gaged: ● At the central control cabinet ● With the remote control in the “Lighting” menu Figure 38: Warning light on the support leg 3.5.10 Spotlights for lighting the support areas...

  • Page 192: Emergency Stop Button

    General technical description Figure 39: Position of the switch / overview of the spotlight range 3.5.11 EMERGENCY STOP button WARNING Lowering placing boom Although all required electric hydraulic valves are de-energised after pressing the EMERGENCY STOP button, this cannot prevent unex‐ pected lowering.

  • Page 193: Emergency Stop Button

    General technical description There are several EMERGENCY STOP on the machine: BUTTONS ● On each support control block ● On the control panel or control cabinet ● On the hopper ● On the remote control Familiarize yourself with the positions of the EMERGENCY STOP buttons on your machine.
  • Page 194 General technical description 3.5.11.2 Starting up the pump after EMERGENCY STOP If you have pressed an EMERGENCY STOP , you can start BUTTON the pump up again using the control panel by the steps as descri‐ bed below: 1. Hold down and turn the EMERGENCY STOP in order to BUTTON unlock it.

  • Page 195: Magnetic Switch Distributor Casing

    General technical description 3.5.12 Magnetic switch distributor casing The distributor casing for the magnetic switches is located on the drive cylinders of the concrete pump. The following illustration shows an example. Figure 41: Setup of the magnetic switch distributor casing Item Designation Schematic illustration of the magnetic switch installation locations and...

  • Page 196: Magnetic Switch Connector

    General technical description the magnetic switches. The indicator lights for the magnetic switches that have just been triggered light up on the distributor casing at the same time. Indicator light Magnetic switch status lights up briefly during switch‐ Magnetic switch is OK over does not light up during switch‐...
  • Page 197 General technical description 3.5.13 Magnetic switch connector The connector for the magnetic switch has one yellow and one green LED. These LEDs indicate the status of the connector and the mag‐ netic switch. Figure 42: Magnetic switch connector Item Designation Green and yellow LEDs Connector Magnetic switch...

  • Page 198: Agitator Safety Cutout (Rsa)

    General technical description Yellow LED Magnetic switch status lights up briefly during switch‐ Magnetic switch is fully function‐ over does not light up during switch‐ Magnetic switch is defective, re‐ over place at earliest opportunity lights up continuously Magnetic switch is defective. Disconnect the magnetic switch connector (because otherwise it is not possible to switch over)
  • Page 199 General technical description Figure 43: Agitator safety cutout – example illustration Item Designation Transponder holder Transponder on the grille Evaluation device on the hopper (behind the transponder) Red and green LEDs Button “Acknowledge agitator safety cutout” Control panel operating panel by the steps The agitator safety cutout triggers the following actions: ●...

  • Page 200: Hydraulic Control Devices

    General technical description The agitator safety cutout is triggered if an evaluation device is de‐ fective. Therefore, always check that the agitator safety cutout is working properly before using the pump. The LEDs on the evaluation device indicate the following: ●...
  • Page 201 General technical description 3.6.1 Support control block 3.6.1.1 Setting up on the left-hand side of the truck is illustra‐ SUPPORT CONTROL BLOCK ted below. The on the righthand side of the SUPPORT CONTROL BLOCK truck is a mirror image of this one. Figure 44: Levers on the support control block Item Designation...
  • Page 202 General technical description Spirit level WARNING Risk of death caused by the machine toppling over 1. Support the machine at a maximum gradient of 3° to ensure that it remains stable. 2. Observe the spirit level when extending the support feet. 3.
  • Page 203 General technical description Spring-loaded The hydraulic support valves are spring-loaded, i.e. the valves are au‐ tomatically reset to the zero position when you release the LEVERS Direction of actuation Figure 46: Direction of movement of the operating lever must be moved upwards and downwards or towards LEVERS and away from the operator to execute the support functions, de‐...

  • Page 204: Pump Control System

    General technical description WARNING Risk of injury If unauthorised persons have access to the boom control block, they could cause the placing boom to move unexpectedly. 1. Fit the cover on the boom control block. 2. Lock the stowage compartment. Figure 47: Boom control block with cover 3.6.3 Pump control system...
  • Page 205 General technical description Depending on the equipment on the machine, the pump control system may be fitted at a different location. You will find the loca‐ tion in the overview at the start of this chapter. It may also be the case that the pump control system is fitted rotated through 90°.

  • Page 206: Centralized Gauge Ports

    General technical description 3.6.4 Centralized gauge ports NOTICE Risk of damage caused by connecting the low-pressure gauge in‐ correctly. Risk of destruction of the low-pressure gauge caused by connecting the low-pressure gauge to a high-pressure measuring point that is marked in red. ▶...

  • Page 207: Other Components

    1. Fit only permissible end hose combinations to the boom tip. 2. Use only Putzmeister end hoses in accordance with the ma‐ chine card. 3. Use only Putzmeister end hose squeeze valves.
  • Page 208 General technical description Do not change or replace the attachments on the boom tip unless (Exclusion of liability this has been authorised by Putzmeister P. 2 — 16) . Use only attachments that have been approved by Putzmeister. The maximum permitted weight for attachments on the boom tip is in‐...
  • Page 209 General technical description Figure 51: Attachments on the boom tip Item Designation Delivery line bend Clamp coupling End hose Retaining rope The following end hose variants are compatible with this machine: 3 — 145 210110691_2018-09-19_EN Operating Instructions...
  • Page 210 End hose with concrete brake End hose with end hose squeeze valve Dual-section end hose with end hose squeeze valve Contact Putzmeister if you wish to fit attachments that are not fitted to the machine at the factory. 3 — 146...
  • Page 211 General technical description 3.7.1.1 Boom tip The gross weight of all attachments and the delivery line elements at the boom tip including concrete filling must not exceed the maximum loadbearing capacity of the placing boom. The boom tip is used as a calculation interface.
  • Page 212 General technical description The permitted gross weight of the end hose, including the concrete filling, can be found in the machine documentation. The machine card for this machine will tell you which end hose is approved for the machine. The maximum permitted end hose length is also indi‐ cated on the placing boom rating plate.
  • Page 213 General technical description Check the retaining rope for damage every day. A damaged retain‐ ing rope must be replaced by a new retaining rope immediately. Figure 54: Overview of the end hose securing device Item Designation Snap hook Retaining rope Push-on connection Hose clamp Protective sleeve with Velcro fastener...
  • Page 214 General technical description Figure 55: Position of the protective sleeve Item Designation Delivery hose Protective sleeve Clamp coupling Velcro fastener End hose 3.7.2 Squeeze valve The squeeze valve is pulled onto the end hose or folded around it and is used to interrupt the flow of concrete so that no concrete leaks out of the delivery line during brief breaks in pumping.
  • Page 215 General technical description WARNING Risk of injury from bursting squeeze valve The pressure limiting valve is set ex works to a limitation of 3 bar. At a higher pressure, the squeeze valve is subjected to too much stress and can burst. ▶...
  • Page 216 General technical description 3.7.2.1 Squeeze valve with rubber sleeve Figure 56: Squeeze valve structure Item Designation Compressed air supply to shutoff valve Pressure limiting valve with pressure gauge Squeeze valve (open) Squeeze valve (closed) End hose coupling with retaining eyes and angular distributor for com‐ pressed air Safety cables with tension springs End hose...
  • Page 217 General technical description 3.7.2.2 Squeeze valve with folding sleeve Figure 57: Squeeze valve structure Item Designation Compressed air hose Tension spring Threaded coupling Hose belt Folding sleeve Compressed air port Locking bolt with spring pin 3.7.2.3 Special features of the squeeze valve The squeeze valve is pulled over the end hose or folded around it and secured with 2 safety cables or tension springs to the retaining eyes of the end hose coupling.
  • Page 218 General technical description A shutoff valve, which needs to be opened in order to supply the squeeze valve with compressed air, is integrated in the supply line. You can switch on the squeeze valve on the remote control. If the “Squeeze valve” function is activated, the actual start of pumping is delayed.
  • Page 219 General technical description Figure 58: Flushing water pump structure Item Designation Hydraulic motor Leakage fluid line Return line Pressure line Connector for water hose Flushing water pump Pressure gauge for water pressure (optional) Drain cock 3 — 155 210110691_2018-09-19_EN Operating Instructions...
  • Page 220 General technical description 3.7.4 Highpressure water pump The high-pressure water pump generates the pressurised water used to clean the machine. Figure 59: High-pressure water pump structure Item Designation Cleaning gun Lance Spray nozzle Pressure gauge Manual emergency operation High-pressure hose Water drain cock Air vent cock Shut-off valve...
  • Page 221 General technical description Designation Value Water temperature 60 °C Supply pressure 8 bar The high-pressure water pump is equipped with a pressure dump valve which is set to 100 bar. If the cleaning gun is closed and the pressure in the water system rises above 100 bar, the pressure dump valve opens a bypass to the intake side of the high-pressure water pump.
  • Page 222 3. You must rectify damage to the delivery piston/drive cylinders immediately. Putzmeister accepts no warranty claims for dam‐ age to the machine resulting from failure to properly observe the maintenance regulations.
  • Page 223 General technical description 3.7.5.1 Without remote operation Figure 60: Position and structure of the water box, without remote operation Item Designation Plan view of the machine Water box fill shut-off valve Water outlet Lid with seal Water box 3.7.5.2 With remote operation There are devices near the hopper to help you fill or drain the water box.
  • Page 224 General technical description Figure 61: Operating elements of the water box with remote operation (example) Item Designation Black mushroom-head button for filling the water box (depending on equipment). Lever for draining the water box (depending on equipment). Locally latched toggle switch for filling the water box (depending on equipment).
  • Page 225 General technical description Figure 62: Vibrator structure Item Designation Grille Vibrator Supply line Plug You can switch the vibrator on and off at the following locations: ● Remote control ● Control panel by the steps 3.7.7 Hydraulic fluid radiator The machine is fitted with a hydraulic fluid radiator with 2 fans. Some of the hydraulic fluid in the machine first flows through this hydraulic fluid radiator before it returns to the filter.
  • Page 226 General technical description Figure 63: Hydraulic fluid radiator Item Designation Boom return circuit fluid Agitator return fluid Flushing fluid Radiator with 2 fans Temperature sensors Leakage fluid Hydraulic fluid reservoir 3 — 162 Operating Instructions 210110691_2018-09-19_EN...
  • Page 227 General technical description Figure 64: Hydraulic fluid radiator with 2 fans Item Designation Symbol for hydraulic fluid radiator Hydraulic fluid return from the radiator Hydraulic fluid to the radiator Temperature sensor 70 °C 3.7.7.1 Special features of the hydraulic fluid radiator control system The hydraulic fluid radiator control system acts as the cooling system for the hydraulic fluid when only the placing boom is being moved or only the concrete pump is being operated.
  • Page 228 General technical description If you wish to cool the hydraulic fluid before it reaches 70 °C as a preventative measure, you can switch the fans on and off on the remote control, regardless of the temperature. As soon as the fans begin running, this is shown on the remote control.
  • Page 229 General technical description The folding steps are each locked in placed using a spring return stop pin. You must pull out the stop pin in order to fold the steps. The stop pin automatically engages and locks the folding steps in place when they are in the folded up or folded down position.
  • Page 230 General technical description (1) must be folded out. The stop During driving, the folding rear lights (2) must be inserted on both sides and secured using the spring pins (3) . pins 3.7.11 Ballast The machine may be outfitted with ballast to ensure that it stays sta‐ ble.
  • Page 231 General technical description Figure 67: Ballast in the hopper area Item Designation Ballast in the hopper area 3 — 167 210110691_2018-09-19_EN Operating Instructions...
  • Page 232 3 — 168 Operating Instructions 210110691_2018-09-19_EN...
  • Page 233 Driving, towing and loading In this chapter you will find information concerning safe transport of the machine. 4 — 1 210110691_2018-09-19_EN Operating Instructions...
  • Page 234 4 — 2 Operating Instructions 210110691_2018-09-19_EN...

  • Page 235: Driving, Towing And Loading

    Driving, towing and loading Driving Truck-mounted concrete pumps may only use public roads if properly approved. The driver must be in possession of the appropriate driving licence. 1. Ask for a signaller if you need to reverse. 2. If necessary, have the route blocked or secured by assistants. 3.
  • Page 236 Driving, towing and loading 8. Disengage the power takeoff. 4.1.1.1 Folding out the rear lights WARNING Risk of accident if the rear lights are not folded out 1. Always leave the rear lights folded out while driving and also while parked, so that the rear lights and reflectors are clearly visible for all other road users.
  • Page 237 Driving, towing and loading 3. Fold the two rear lights out. (1) . 4. Lock the rear lights on both sides using the lock pins (2) . 5. Secure the lock pins using the spring pins 4.1.2 During the journey Figure 69: The machine must not be driven with the placing boom unfolded The size and weight of the truck demand particular caution when driv‐...
  • Page 238 Driving, towing and loading Figure 70: Position of the warning signal and operating elements Item Designation Acoustic warning signal Boom cradle switch Transponder on the placing boom Reading head (at the boom cradle – example figure) (Shifting 1. Place the placing boom correctly on the boom cradle. the placing boom to the driving position P.
  • Page 239 Driving, towing and loading Hand signals for driving It is often necessary to have a signaller help by directing you when 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 240 Driving, towing and loading 4.2.3 Hand signal for turning right ▶ With the arm crooked, point with the thumb in the direction of travel. 4.2.4 Hand signal for driving towards the signaller ▶ With the arm crooked, wave the palm in the direction of travel. 4 —...
  • Page 241 Driving, towing and loading 4.2.5 Hand signal for driving away from the signaller ▶ With the arm crooked, wave the palm in the direction of travel. 4.2.6 Hand signal for the distance to the obstacle ▶ With the arm crooked, indicate the distance to an obstacle with the palms of the hands.
  • Page 242 Driving, towing and loading The truck may only be towed in accordance with the truck manu‐ facturer’s instructions. Figure 72: Example illustration of a towing coupling on the front of the truck ▶ Tow the machine by the towing gear on the front of the truck. 4.3.2 Recovery WARNING...
  • Page 243 Driving, towing and loading Figure 73: Lashing point at the rear of the truck ▶ Only use the lashing point on the rear of the truck for assistance on the construction site if a tow-bar cannot be fitted to the front of the truck.
  • Page 244 The machine can fall from the lifting equipment if it is lifted using im‐ permissible lifting eyes. ▶ Only load the machine if the Putzmeister lifting eyes for your machine are present on the swinging support legs. You can order the lifting eyes for your machine from the Putzmeis‐...
  • Page 245 Driving, towing and loading NOTICE Damage caused by the lifting tackles Delivery lines can be damaged if they come into contact with lifting tackles during craning. 1. Keep the lifting tackles under constant observation while they are being tightened. 2. Remove any delivery lines that would come into contact with lift‐ ing tackles during craning.
  • Page 246 Driving, towing and loading Figure 75: Example overview: Craning data Item Designation Angle from the perpendicular Forward lifting eye Rear lifting eye 4.4..1 Technical data Designation Value Permissible gross machine weight dur‐ 35 t ing craning Load-bearing capacity of the forward each 10 t lifting eyes Length of the forward lifting tackle...
  • Page 247 Operation 5 — 1 210110691_2018-09-19_EN Operating Instructions...
  • Page 248 5 — 2 Operating Instructions 210110691_2018-09-19_EN...
  • Page 249 Operation Starting up Starting up and de-commissioning the machine may only be carried out by an experienced machine operator. Operation, cleaning and maintenance of the machine may only be carried out by trained and instructed personnel. Prerequisites: ✓ When taking over the machine, you have become so familiar with the device that damage and accidents cannot occur.
  • Page 250 Operation 5.1.2 Checking functional fluids WARNING Risk of injury Auxiliary materials or functional fluids can cause poisoning, chemi‐ cal burns or irritation. 1. Take note of the safety data sheets for the auxiliary materials or functional fluids used. 2. Wear personal protective equipment. 3.
  • Page 251 Operation Figure 76: Water, oil and fuel levels The water box must be filled during operation, even if there is a risk of freezing. 1. Check the fill levels of all functional fluids. 2. Refill the functional fluids if necessary. (Checking the lubricating pressure 3.
  • Page 252 Operation On some truck models, all hydraulic pumps are driven by clutch‐ dependent NA power takeoffs. In these cases, the boom hydraulic pump is driven by NA 1, and the concrete pump hydraulic pump by NA 2. Prerequisites: ✓ You have read the truck manufacturer's Operating Instructions. ✓...
  • Page 253 Operation 5.1.3.1 Operating and control elements for power take-offs This illustration shows examples of operating and control elements for power take-offs. Number, appearance and location can differ in truck models by different truck manufacturers. Figure 77: Operating and control elements Item Designation Indicator light in the dashboard: Power take-off switched on...
  • Page 254 Operation 1. Depress the clutch pedal. 2. Wait a few seconds. 3. Switch on 1 or 2. POWER TAKE OFF SELECTOR ⇒ The indicator lamp in the dashboard lights up. 4. Release the clutch pedal again slowly. To switch off the power take-offs, use the reverse sequence. 5.1.4 Setting up the remote control The remote control can be used both as a radio remote control and...
  • Page 255 Operation 5.1.4.2 Connecting the remote control as a cable remote control Figure 78: Remote control system Item Designation Central control cabinet Radio base station Remote control Operating mode selector switch Remote control cable (for optional use as a cable remote control) 1.
  • Page 256 Operation 5. Press the “Deactivate EMERGENCY STOP” twice, holding BUTTON it down for a longer period the second time. ⇒ The remote control is switched on. 6. Press the “Deactivate EMERGENCY STOP” briefly. BUTTON ➙ The EMERGENCY STOP is deactivated. ➙...
  • Page 257 Operation Figure 80: Push the battery into the battery compartment 5. Pick up the charged battery and hold it as shown. ⇒ The label is located on the rear of the battery. ⇒ The terminals are located on the right-hand side of the battery. 6.
  • Page 258 Operation Charging the battery with a separate charger Figure 81: Construction of the separate charger Item Designation Battery Indicator lights Charging compartment Power cable (example) Indicator light Description Red indicator light Battery is in a state of deep discharge or is defective Yellow indicator light Battery is charging Green indicator light...
  • Page 259 Operation Storing batteries CAUTION Risk of injury due to fire caused by sparking on the batteries Risk of burning if the terminals of the batteries come into contact with metal and sparks which could trigger a fire are generated. ▶ Cover the battery terminals with the protective caps provided before you store or carry the battery outside the battery com‐...
  • Page 260 Operation Figure 83: Removing and inserting the “i-Log” 1. Make sure that both remote controls are switched off. 2. Using a flat screwdriver or similar tool, carefully remove the “i- Log” from the remote control. 3. Position the remote control that you wish to use in front of you. 4.
  • Page 261 Operation 5.1.5 Acknowledging the agitator safety cutout WARNING Risk of injury The agitator can start up unexpectedly. 1. Do not tamper with the agitator safety cutout. 2. The machine must only be operated if the agitator safety cutout is intact. The agitator is secured against unexpected restarts.
  • Page 262 Operation Figure 84: Control panel by the steps Item Designation Button “Acknowledge agitator safety cutout” 1. Press “Acknowledge agitator safety cutout”. When restarting, proceed as follows: 2. Switch off the core pump. 3. Switch on the core pump. 5 — 16 Operating Instructions 210110691_2018-09-19_EN...
  • Page 263 Operation Centralised lubrication system The centralised lubrication system integrated in your machine func‐ tions automatically, i.e. the machine is lubricated at fixed programmed intervals. Figure 85: Centralized lubrication system structure Item Designation Lubricant reservoir Air bleeder Grease gun Filler nipple Lubricant pump 5.2.1 Operating the centralised lubrication system...
  • Page 264 Operation Dirt in the system leads to faults. 5. Keep the system clean. 5.2.2 Filling the lubricant reservoir The lubricant reservoir may be filled up to the “MAX” mark via the fill‐ ing nipple or from above through the filler opening. CAUTION Risk of injury The lubricant reservoir could burst if it is overfilled.
  • Page 265 Operation 5.2.2.1 Filling the lubricant reservoir using a grease gun In many cases, the filler nipple of the lubricant reservoir is exten‐ ded with a hose and fastened to the truck superstructure so that the lubricant reservoir can be filled more easily. (3) to the filler nipple (4) on the lubricant 1.
  • Page 266 Operation To initiate a manual pump lubrication process using the remote con‐ trol in remote operation: 1. Press the “Start a single pump lubrication process” in the BUTTON “Cleaning” menu. ▶ Press the “Manually lubricate the core pump” in the “User- BUTTON defined pump lubrication”...
  • Page 267 Operation Figure 86: Pressure gauge for lubricating pressure Item Designation Hopper Pressure gauge for lubricating pressure Working pressure range of the centralised lubrication system Working pressure range of the centralised lubrication system Designation Value Minimum working pressure 20 bar Maximum working pressure 80 bar ▶...
  • Page 268 Operation WARNING Risk of injury in the swing-out and extension zone of the support legs There is a risk of injury as a result of crushing, impact, entangle‐ ment and shearing of various body parts caused by swinging and extending the support legs. 1.
  • Page 269 Operation WARNING Risk of injury if hydraulic lines and/or threaded unions on the sup‐ port legs are not leak-tight Risk of injury to body parts as a result of crushing, impact or falling, caused by unexpected movement of the support legs if hydraulic lines and/or threaded unions on the support legs are not leak-tight.
  • Page 270 Operation 5.3.2 Setup site WARNING Risk of death caused by exhaust gases in closed or low buildings Risk of breathing difficulties, asphyxiation, intoxication, lung dam‐ age or carbon monoxide poisoning. 1. Set the machine up at an adequately ventilated site or vent the exhaust gases away from where you are working.
  • Page 271 Operation 5.3.2.1 Space requirement Figure 88: Correct and incorrect way to swing out or extend the support legs 5.3.2.2 Lighting The setup site must have sufficient lighting to ensure safe operation of the machine. ▶ Ensure that the setup site is adequately lit. 5.3.2.3 Minimum clearance from pits When supporting the machine, a minimum clearance from pits must...
  • Page 272 Operation WARNING Risk of death due to the machine slipping Risk of injury to various parts of the body by crushing, impact and shearing caused by the machine slipping. If the supporting ground has insufficient load-bearing capacity or there is inadequate clear‐ ance from pits or slopes, the machine will no longer be stable.
  • Page 273 Operation ▶ Maintain the minimum clearance “a” even for a low-depth pit and ground with a high loadbearing capacity. 5.3.2.4 Safe clearance from pits The safe clearance A ● for loose, backfilled soil is A ≥ 2 × pit depth T. ●...
  • Page 274 Operation 5.3.2.5 Supporting ground WARNING Risk of death due to a loss of machine stability Risk of death and injury to various parts of the body by crushing, im‐ pact and shearing caused by loss of machine stability because the supporting ground has insufficient load-bearing capacity.
  • Page 275 Operation Figure 92: Only support on level supporting ground 5.3.2.6 Support area WARNING Risk of death caused by the machine toppling over Risk of death and risk of various body parts being crushed or in‐ jured from impact caused by the machine toppling over if incorrectly operated while being supported, provided with additional support or if a support leg is left suspended in the air.
  • Page 276 ▶ When supporting the machine, always use Putzmeister support plates. 1. Support the machine according to the corner bearing loads and the loadbearing capacity of the supporting ground (permissible ground pressure).
  • Page 277 ÷ support area (= support plate area) 0.36 m = maximum possible ground pressure 444 kN/m In this example, using Putzmeister support plates (60 cm × 60 cm) as a base is sufficient. 5.3.2.8 Length of the timber blocks required The following section describes the correct selection of the required timber blocks.
  • Page 278 Operation WARNING Risk of death caused by the machine toppling over if a support leg slides away from greasy timber blocks 1. Always use four timber blocks, each with a cross section of 15 cm × 15 cm. 2. Check that support plates are always free of grease, oil, ice, etc.
  • Page 279 5. For example, take the timber block length from the 200 kN col‐ umn in the table, if the actual corner bearing load of the machine is 180 kN. Examples * = With Putzmeister support plates 5 — 33 210110691_2018-09-19_EN Operating Instructions...
  • Page 280 Firmly settled gravel Permissible ground pressure 400 kN/m Machine corner bearing load 150 kN Timber block length not required In this example, using Putzmeister support plates (60 cm ×60 cm) as a base is sufficient. 5 — 34 Operating Instructions 210110691_2018-09-19_EN...
  • Page 281 Operation Corner bearing load in kN (see support leg) Permissible ground Timber block lengths in cm pressure kN/m Untreated ground surfaces Asphalt (minimum 20 cm thick) Hardcore (compac‐ ted) Example Clayey, coarse clay (firm) Mixed composition (firm) Bedded gravel (firm) Bedded gravel (firm) Designation Value...
  • Page 282 Operation In this example, in addition to the Putzmeister support plates (60 cm × 60 cm), you must place four timber blocks with a cross section of 15 cm × 15 cm and a length of at least 100 cm under‐...
  • Page 283 Operation WARNING Risk of injury in the swing-out and extension zone of the support legs There is a risk of injury as a result of crushing, impact, entangle‐ ment and shearing of various body parts caused by swinging and extending the support legs. 1.
  • Page 284 Operation The “Support monitoring” safety system checks the following parame‐ ters: ● the position of the support legs ● the raising of the truck axles ● the gradient and distortion of the machine Depending on this check, the safety system enables a working range or an extended placing boom working range for specific machines.
  • Page 285 Operation 5.3.3.1 Working area WARNING Risk of injury to unauthorized persons in the working area 1. Secure the working area. 2. Keep the working area under constant observation. 3. You must cease working immediately and press the EMER‐ GENCY STOP button if unauthorized persons enter the working area.
  • Page 286 Operation Information regarding the working area, support variant, gradient of the machine, raise monitoring and faults can be found on the re‐ mote control in the “Support” menu and its “Spirit level” submenu. You must first switch on the support functions before you can support the machine.
  • Page 287 Operation Figure 99: Unlocking the snaplock You must unlock the support legs before you are able to extend them or swing them out. 1. Pull out the spring pin (1.). 2. Open the snaplock using the (2.). LEVER 3. For extendable support legs, refit the spring pin after the support legs have locked in place.
  • Page 288 Operation The electronic spirit level does not rotate with the machine opera‐ tor. Prerequisites: Ensure that you are familiar with the method of operation of the elec‐ (“Spirit level” menu P. 3 — 70) tronic spirit level. ▶ Correct the gradient of the machine by providing additional sup‐ port.
  • Page 289 Operation ⇒ Have any damage rectified immediately by Putzmeister quali‐ fied personnel. Damage has also occurred if the displays in the two spirit levels differ. 5.3.3.7 Extend supports – full support WARNING Risk of death due to the support legs being incorrectly extended 1.
  • Page 290 Operation Extending the forward support legs Figure 101: Extending the forward support legs Item Designation Support function on Extend and retract the forward support leg Proceed as follows to extend the forward support legs: 1. Operate the “Support function on” LEVER ⇒...
  • Page 291 Operation Extending the rear support legs Figure 102: Swinging the rear support legs Item Designation Support function on Swing the rear support leg in and out Proceed as follows to swing out the rear support legs: 1. Operate the “Support function on” LEVER ⇒...
  • Page 292 Operation Lowering the forward support feet Figure 103: Lowering the forward support feet Item Designation Support function on Raise and lower the forward support foot Proceed as follows to lower the forward support feet: 1. Operate the “Support function on” LEVER ⇒...
  • Page 293 Operation Lowering the rear support feet Figure 104: Lowering the rear support feet Item Designation Support function on Raise and lower the rear support foot Proceed as follows to lower the rear support feet: 1. Operate the “Support function on” LEVER ⇒...
  • Page 294 Operation 5.3.3.8 Extending supports – Restricted support WARNING Risk of death caused by the machine toppling over The machine can topple over more easily if its support is limited. 1. When working with limited support, proceed exactly as descri‐ bed in the instructions and work with great care. 2.
  • Page 295 Operation ➙ You have supported the telescopic support leg in an intermediate position. Moving the swinging support leg into the intermediate position Proceed as follows to move a swinging support leg into a defined in‐ termediate position: 1. Swing the swinging support leg outwards by at least 0.2 m. The machine must be completely raised, so that the wheels are not in contact with the ground.
  • Page 296 Operation 5.3.3.9 Switching off the support function Figure 105: Operating mode selector switch The support function must be switched off before operations can con‐ tinue. The machine must always be standing level and firmly on the ground. Continue to observe the spirit level and the supports whilst operat‐ ing the pump.
  • Page 297 Operation Additional support can be provided to the machine in any boom posi‐ tion. The gradient of the supported machine is saved in the control system and displayed on the remote control screen in the ““Spirit lev‐ el”” menu. If a gradient change of (+/- 0.5°) occurs for more than 10 seconds, or if the permissible gradient range (+/−...
  • Page 298 Operation If, because of local conditions, you cannot maintain the machine's gradient or ensure that the machine is fully raised, you can activate ““Process monitoring mode 1””. If the permissible gradient (+ 3°) is exceeded or the full number of additional support options has been reached, support monitoring switches support leg movement permanently off.
  • Page 299 Operation CAUTION Risk of crushing The folding steps come close to the rear lights when being folded up, which can result in limbs being crushed. ▶ When folding them up or down, grip the folding steps on the side that faces away from the rear lights. If the folding steps have been folded down: 1.
  • Page 300 Operation 5.5.1.2 Magnetic switch Figure 107: Checking the magnetic switches ▶ Check whether the drive cylinders switch over automatically as soon as the hydraulic pistons approach the magnetic switch. ⇒ The green in service light on the distributor casing lights up permanently.
  • Page 301 Operation ⇒ The next time the transfer tubes are switched over, the first single stroke is complete. 4. Take the measurement over a period of 10 single strokes. ⇒ The measured value divided by 10 must be the same as the data in the test reading.
  • Page 302 Operation Figure 108: Display on the screen Item Designation Vacuum return flow filter warning indicator ▶ Check the screen to see whether the vacuum return flow filter el‐ ement needs replacing. ➙ The “Vacuum return flow filter element clogged” status message is not displayed.
  • Page 303 Operation Figure 109: Vacuum meter 1. Check that the temperature of the hydraulic fluid is at least 30 °C. 2. Inspect the vacuum meter. ⇒ The indicator for the vacuum meter is in the green area. The indicator is in the red area? The vacuum filter impedes the flow of the hydraulic fluid.
  • Page 304 Operation 5.5.3 Operating the EMERGENCY STOP button WARNING Lowering placing boom Although all required electric hydraulic valves are de-energised after pressing the EMERGENCY STOP button, this cannot prevent unex‐ pected lowering. 1. Never press the EMERGENCY STOP button if the placing boom moves unexpectedly, because doing so will prevent you from countering the unexpected movements.
  • Page 305 Operation Figure 110: EMERGENCY STOP button Item Designation Press: Locks EMERGENCY STOP button Turn: Unlocks EMERGENCY STOP button 1. Switch the pump on. 2. Operate a boom function. 3. Press one of the EMERGENCY STOP buttons. ⇒ The pump stops instantly. ⇒...
  • Page 306 Operation Inspection Interval Intervals for inspection by annually subject expert Interval for function Before the machine is used each time checks WARNING Risk of injury The agitator can start up unexpectedly. 1. Do not tamper with the agitator safety cutout. 2.
  • Page 307 Operation Figure 111: Function check of the agitator safety cutout (RSA) Item Designation Reading head (on the hopper – example illustration) Green and red LEDs Transponder (on the grille) Safety action: ● The accumulator dump valve is opened and the accumulator is emptied.
  • Page 308 Operation 5.5.5.2 Function check Figure 112: Agitator safety cutout function check 1. Open the grille with the core pump running. 2. Stop working if one of the safety actions is not carried out after opening the grille. 5.5.5.3 Acknowledging the agitator safety cutout WARNING Risk of injury The agitator can start up unexpectedly.
  • Page 309 Operation The agitator safety cutout is triggered by the following actions: ● Opening the grille ● Activating the EMERGENCY STOP ● Switching off the power take-off ● Switching off the ignition Figure 113: Control panel by the steps Item Designation Button “Acknowledge agitator safety cutout”...
  • Page 310 3. Do not lift any loads with the placing boom. 4. Do not extend the placing boom. 5. Do not extend the end hose. 6. Use only a Putzmeister end hose in accordance with the ma‐ chine card. 7. Release trapped end hoses manually.
  • Page 311 Operation WARNING Risk of death from the arms dropping In contravention with the instructions, if the end hose is located above the D hinge, the rod-side hydraulic pressure in the D cylinder will become too high. As a result, the pressure limiting valve is acti‐ vated and the placing boom slowly drops.
  • Page 312 Operation CAUTION Risk of injury The placing boom can swing into the machine or obstacles in its surroundings. People may be injured by machine components or concrete. 1. Only fold the placing boom to the minimised load position if it is swinging due to external influences.
  • Page 313 Operation WARNING Risk of death The placing boom can break at excessive wind speeds. The machine may topple over. 1. Placing booms with a vertical reach of 42 m or more must only be operated in conditions up to and including wind force 7 (wind speed of 51 km/h = 14 m/s).
  • Page 314 Operation 5.6.2.2 Cold weather WARNING Risk of death At ambient temperatures below -15 °C, parts of the placing boom that have undergone brittle fracture can fall. ▶ Only operate the machine at ambient temperatures above - 15 °C. WARNING Risk of death Additional materials may cause the placing boom to break or the machine to topple over.
  • Page 315 Operation 5.6.3 Danger zone WARNING Risk of injury Persons in the working area or the placement site could be injured if you are not able to see the entire working area of the placing boom. 1. Always maintain visual contact with the placement site and with the working area of the placing boom.
  • Page 316 Operation 5.6.3.1 High-voltage lines WARNING Risk of death due to fatal electric shock Risk of death due to a fatal electric shock if the placing boom comes into contact with a high-voltage line. 1. Only set up the machine at a sufficient distance from high-volt‐ age lines.
  • Page 317 Operation 5.6.3.2 Overlapping working ranges WARNING Risk of injury due to collision of the arm assembly with the sur‐ rounding area or other large-scale devices Risk of falling, being crushed or suffering impact from falling parts if the arm assembly collides with surrounding objects or other large- scale devices.
  • Page 318 Operation 5.6.3.3 Signalling boom movements Figure 118: Sound the horn first, then move 1. Signal a warning by sounding the horn before you move the plac‐ ing boom. 2. Control the placing boom carefully. 3. Maintain visual contact with the placing site. 5.6.3.4 Hand signals (Hand signals for pumping operations P.
  • Page 319 Operation 2. If this is not the case, have a signaller assist you with hand sig‐ nals. 3. Agree clear hand signals with the signaller. 5.6.4 Independent retracting of the hydraulic cylinders WARNING Risk of death The volume of the hydraulic fluid in the support cylinders can re‐ duce unexpectedly.
  • Page 320 Operation Figure 120: Effects of volume reduction (Driving position P. 5 — 150) 1. Move the placing boom into the driving position before taking a break from working. 5.6.5 Spontaneous slewing of the placing boom The placing boom could slew spontaneously if the slewing gear brake is overloaded due to excessively strong wind or an excessively high machine gradient.
  • Page 321 Operation 5.6.5.1 Moving the placing boom into a reduced load position Folding the placing boom reduces the load on the slewing gear brake. NOTICE Material damage ▶ Follow the instructions for raising and lowering the placing boom. ▶ Move the boom tip as far as possible towards the slewing gear. ⇒...
  • Page 322 Checking the slewing gear brake If the placing boom has spontaneously slewed, the slewing gear brake must be checked. ▶ Have the slewing gear brake checked by a Putzmeister service technician or authorised personnel. ⇒ The Putzmeister service technician or authorised personnel will decide whether the slewing gear brake needs to be re‐...
  • Page 323 Operation ● Lines, threaded unions or boom cylinders leaking ● Defective isolator on the boom cylinder ● Hydraulic system not carefully vented ● Insufficient hydraulic fluid in the reservoir ● Cooling of the hydraulic fluid If it is defective, the placing boom may move as soon as the remote control is switched on.
  • Page 324 Operation WARNING Risk of injury The placing boom can lower if there is air or a vacuum in the sys‐ tem. 1. Ensure that the tank is always sufficiently full of hydraulic fluid. 2. Fill the hydraulic system correctly and inspect it regularly. 3.
  • Page 325 Operation Unfolding the placing boom After the machine has been supported, you can switch over to “Boom functions” on the remote control. The unfolded placing boom can be moved around within the working area. The placing boom can be moved around within the extended working area with Arm 1 in a vertical position.
  • Page 326 Operation 2. Fold down Arm 2, Arm 3 and Arm 5 momentarily. Figure 121: Unfolding Arms 1 and 2 Item Designation Unfolding Arm 1 Unfolding Arm 2 3. Unfold Arm 1 approximately 70 °. If necessary: 4. Slew the placing boom in the required direction. 5.
  • Page 327 Operation If the machine is equipped with end hose brackets without locking mechanisms, you will require more clearance beneath the placing boom when this is being unfolded to ensure that the end hose does not scrape along the ground. Figure 122: Unfolding Arm 3 6.
  • Page 328 Operation Figure 123: Unfolding Arm 5 7. Unfold Arm 5 approximately 15 °. Figure 124: Unfolding Arms 4 and 5 8. Unfold Arm 4 and Arm 5. ➙ You have unfolded the placing boom. 5 — 82 Operating Instructions 210110691_2018-09-19_EN...
  • Page 329 Operation You can unlock the end hose. 5.7.1.1 End hose brackets without locking mechanisms Figure 125: Unfolding Arm 4 1. Unfold Arm 4. Figure 126: Unfolding Arm 5 2. Unfold Arm 5. ➙ The end hose falls from the end hose bracket. 5 —...
  • Page 330 Operation 5.7.1.2 End hose brackets with locking mechanisms CAUTION Risk of injury from the end hose falling when folding and unfolding the placing boom Risk of fingers, hands and head being crushed or hit by the end hose falling down. This risk occurs if the gravitational force acting on the end hose causes it to unlock while the placing boom is un‐...
  • Page 331 Operation Figure 128: Unfolding Arm 5 ▶ Unfold Arm 4 and Arm 5 enough to allow you to unlock the end hose. 5.7.1.3 Unlocking the end hose CAUTION Risk of injury from unlocking the end hose catch bracket by hand (spring movement) Risk of crushing of fingers and hands if caught by moving parts of the spring when unlocking the end hose by hand.
  • Page 332 Operation Figure 129: Unlocking the end hose ▶ Pull both locking levers downwards. Figure 130: End hose unlocked ➙ You have unlocked the end hose. 5.7.2 Unfolding the placing boom with limited support If you have set up the machine using limited support, you must only unfold the placing boom as described below.
  • Page 333 Operation (Boom movements P. 5 — 63) ✓ You have familiarised yourself with the instructions for folding and unfolding the placing boom. (Unfolding the placing boom P. 5 — 79) The hydraulic fluid warms up when you fold the placing boom. It cools back down later, causing the pressure in the cylinder to drop.
  • Page 334 Operation ° Figure 131: Raising the placing boom to a vertical position 3. Move the placing boom into the vertical position. If the placing boom is located outside a working area, you can move the placing boom in a minimized load position over the area without support into the working area.
  • Page 335 Operation Figure 132: Slewing the placing boom into the working area 4. Slew the placing boom into the previously selected working area. 5. Continue to unfold the placing boom, as described in the section “Unfolding the placing boom with full support”. 5 —...
  • Page 336 Operation Hand signals for pumping operations Clear hand signals must be agreed between the machine operator and the signaller before start of work. Suggestions for the most impor‐ tant hand signals are made in this chapter. The direction of move‐ ment should be taken to be from the direction of view of the machine operator.
  • Page 337 Operation 5.8.3 Hand signal for move slowly Figure 135: Slow ▶ Place one fist on your hard hat. 5.8.4 Hand signal for turning the placing boom anti-clockwise Figure 136: Boom anti-clockwise ▶ Indicate the direction of rotation using your outstretched arm. 5 —...
  • Page 338 Operation 5.8.5 Hand signal for turning the placing boom clockwise Figure 137: Boom clockwise ▶ Indicate the direction of rotation using your outstretched arm. 5.8.6 Hand signal for Arm 1 up Figure 138: Arm 1 up 1. Hold one arm straight down by your side. 2.
  • Page 339 Operation 5.8.7 Arm 1 down Figure 139: Arm 1 down 1. Hold one arm straight down by your side. 2. Extend the other arm with your thumb pointing downwards. 5.8.8 Hand signal for Arm 2 up Figure 140: Arm 2 up 1.
  • Page 340 Operation 5.8.9 Arm 2 down Figure 141: Arm 2 down 1. Hold one arm down by your side at a 45 degree angle. 2. Extend the other arm with your thumb pointing downwards. 5.8.10 Hand signal for Arm 3 up Figure 142: Arm 3 up 1.
  • Page 341 Operation 5.8.11 Arm 3 down Figure 143: Arm 3 down 1. Extend one arm out to the side horizontally. 2. Extend the other arm with your thumb pointing downwards. 5.8.12 Hand signal for Arm 4 up Figure 144: Arm 4 up 1.
  • Page 342 Operation 5.8.13 Arm 4 down Figure 145: Arm 4 down 1. Hold one arm up at a 45 degree angle. 2. Extend the other arm with your thumb pointing downwards. 5.8.14 Hand signal for Arm 5 up Figure 146: Arm 5 up 1.
  • Page 343 Operation 5.8.15 Hand signal for Arm 5 down Figure 147: Arm 5 down 1. Hold one arm up vertically. 2. Extend the other arm with your thumb pointing downwards. 5.8.16 Hand signal for end hose forwards Figure 148: End hose forwards 1.
  • Page 344 Operation 5.8.17 Hand signal for end hose back Figure 149: End hose back 1. With both arms crooked, move your forearms forwards and back. 2. Hold your palms so that they face away from the body. 5.8.18 Hand signal for end hose to the left Figure 150: End hose to the left ▶...
  • Page 345 Operation 5.8.19 Hand signal for end hose to the right Figure 151: End hose to the right ▶ Point both arms in the direction of movement of the end hose. 5.8.20 Hand signal for end hose up Figure 152: End hose up ▶...
  • Page 346 Operation 5.8.21 Hand signal for end hose down Figure 153: End hose down 1. Move both arms up and down. 2. Keep both index fingers pointing downwards. 5.8.22 Hand signal for increase delivery rate/start of delivery Figure 154: Increase delivery rate or start of delivery 1.
  • Page 347 Operation 5.8.23 Hand signal for reduce delivery rate Figure 155: Reduce delivery rate 1. Point the thumb on one hand downwards. 2. Hold the palm of the other hand under it. 5.8.24 Hand signal for reverse pumping Figure 156: Reverse pumping ▶...
  • Page 348 Operation 5.8.25 Hand signal for stopping the pump Figure 157: Stop pump ▶ Hold both arms above your head with your hands clasped togeth‐ Filling and emptying the water box WARNING Risk of injury due to falling from the machine 1.
  • Page 349 There is a risk that the concrete pump will overheat if the water level is too low. Damage to the delivery pistons or drive cylinders must be rectified immediately. Putzmeister accepts no warranty claims for damage to the machine resulting from failure to properly observe the main‐ tenance regulations.
  • Page 350 Operation 4. Reattach the lid to the water box. 5.9.2 Water box with remote operation Prerequisites: (With remote operation P. 3 — 159) 5.9.2.1 Filling the water box 1. Make sure that the lever for draining the water box is locked in position.
  • Page 351 Operation (Boom movements P. 5 — 63) ✓ You have unfolded the placing boom. (Unfolding the placing boom P. 5 — 79) 5.10.1 Dangers during pumping operations Risks to the life and limb of site personnel can arise at many points during pumping operations.
  • Page 352 Operation WARNING Risk of injury from the end hose vibrating ▶ Guide the end hose using both hands but without holding it tightly. CAUTION Risk of injury from falling concrete residue ▶ Do not stand beneath the end hose. ▶ Observe the safety instructions in order to minimise the risk of ac‐...
  • Page 353 Operation 5.10.1.2 Incorrect use of the end hose Figure 159: Incorrect use of the end hose 1. Never bend the end hose over. 2. Never straighten a kinked end hose by using a pressure increase. 3. Ensure that the end hose is never inserted in the concrete. 4.
  • Page 354 Operation 5.10.1.3 Sucking in air Entrapped air can become compressed air at the end of the delivery line, which can be released suddenly, ejecting the concrete violently. 1. Do not draw any air in. Figure 160: Filling the hopper correctly 2.
  • Page 355 Operation You can request a copy of this brochure from the Putzmeister After Sales department. 5.10.2.1 Seesawing boom 1. Check the support and correct it if the placing boom is seesawing wildly during pumping. 2. Reduce the pump speed or change the boom position if the sup‐...
  • Page 356 Operation When the pump is stopped, only the content of the end hose flows out if the arm position is horizontal; the content of the delivery line can flow out if the arm position is below the horizontal. The strokes of the pump cause forces to act along the delivery line and thus along the placing boom.
  • Page 357 Operation 5.10.4 Starting to pump The process from the start of concrete pumping until the moment when a continuously flowing concrete stream emerges from the end hose is referred to as “starting to pump”. In the case of new delivery lines, or when the delivery line has not been used for a long time, pumping must be started using a ce‐...
  • Page 358 Operation 4. Pour the concrete from the truck mixer, silo, etc. into the agitator hopper. 5. Switch the agitator on. 6. Begin delivery. 7. Start with a low output and increase this continuously after sever‐ al cubic metres. 5.10.5.1 Breaks in pumping CAUTION Risk of injury The volume of the hydraulic fluid decreases as it cools.
  • Page 359 Operation 5. When you begin the pumping process, leave the machine to pump in reverse until the transfer tube switches through fully on both sides. 6. In the case of lengthy breaks in pumping, pump the concrete back into the hopper. 7.
  • Page 360 Operation ● leavings in the transfer tube and delivery line ● unsuitable concrete composition ● segregated concrete ● set concrete 1. In the event of blockages, pump the concrete immediately back into the agitator hopper and mix it up. 2. Switch back over to forward pumping if the delivery cylinders and transfer tube are automatically switching over perfectly once again.
  • Page 361 Operation Cooling NOTICE Material damage Water that contains salt damages the core pump and the chrome layer of the delivery piston rods and delivery cylinders. 1. Never spray the hydraulic fluid reservoir with water. 2. Never cool using sea water or water that contains salt. Figure 165: Cooling the hydraulic fluid 1.
  • Page 362 1. Fit only permissible end hose combinations to the boom tip. 2. Use only Putzmeister end hoses in accordance with the ma‐ chine card. 3. Use only Putzmeister end hose squeeze valves.
  • Page 363 Operation WARNING The placing boom can be overloaded Risk of injury from falling items and spurting concrete. 1. Do not load the placing boom with continuation delivery lines. 2. Continuation delivery lines may only be fitted by trained and qualified personnel. CAUTION Risk of injury The volume of the hydraulic fluid decreases as it cools.
  • Page 364 Operation 1. Move the placing boom with the last arm approx. 1.5 - 2 m to‐ wards the stationary delivery line. 2. Lay the last arm down on suitable supports where possible. 3. Switch the on the remote control OPERATING MODE SELECTOR SWITCH to switch position “0”...
  • Page 365 Operation WARNING Risk of injury The agitator can start up unexpectedly. 1. Do not tamper with the agitator safety cutout. 2. The machine must only be operated if the agitator safety cutout is intact. WARNING Injuries to skin and eyes Conveyed material can spray out.
  • Page 366 Operation Concrete residues deposited around the wear ring can impair its func‐ tion. Therefore, thorough rinsing of the wear ring is important after work is finished, as long as the pump will not be used again within the next 30 - 60 minutes. 1.
  • Page 367 Operation ⇒ The concrete flows into the sheet, and once in the sheet, can be brought to the site of concrete placement using a construc‐ tion site crane. 5.11.1.2 Using concrete residue with a wheelbarrow 1. Fold in the placing boom. 2.
  • Page 368 2. Never point the compressed air gun at people or animals. 3. Wear your personal protective equipment (particularly your pro‐ tective goggles). Putzmeister accepts no liability for damage caused by incorrect im‐ plementation of compressed air cleaning. 5.11.3 Operate the high-pressure water pump The high-pressure water pump generates the pressurised water used to clean the machine.
  • Page 369 Operation CAUTION Risk of injury and damage from pumping incorrect functional fluids 1. Only pump water. 2. Use only commercially available cleaning agents. NOTICE Material damage The water jet of the high-pressure water pump can damage surfa‐ ces. ▶ Maintain a minimum distance of 30 cm between the nozzle and the surface you wish to clean.
  • Page 370 Operation Figure 168: High-pressure water pump structure Item Designation Cleaning gun Lance Spray nozzle Pressure gauge Manual emergency operation High-pressure hose Water drain cock Air vent cock Shut-off valve Prerequisites: ✓ You have familiarised yourself with the operating parameters of the high-pressure water pump.
  • Page 371 Operation 0.3 l of oil with an oil viscosity conforming to SAE 30 is required to fill the oil reservoir completely. 3. Ensure that the water system is depressurised and empty of wa‐ ter before carrying out repair work. 4. Only use water up to a maximum temperature of 60 °C. 5.11.3.1 Switch on the highpressure water pump The high-pressure water pump is fitted with a dry running cut-out.
  • Page 372 Operation 5. Open the air vent cock on the water filter housing to allow the air to escape from the intake line. 6. Close the air vent cock again as soon as water is flowing out steadily. 7. Start up the truck engine and run it at idling speed. (Switch on the high‐...
  • Page 373 Operation 5.11.3.4 After use and when there is a risk of freezing Follow the steps below after each use of the high-pressure water pump. 1. Flush out the water system of the highpressure water system with water if you have used a cleaning agent. 2.
  • Page 374 Operation NOTICE Damage caused by dry running ▶ Switch on the high-pressure water pump a maximum of three successive times without water. 1. Drain off the water via the drain cock. (Switch on the high‐ 2. Switch on the high-pressure water pump pressure water pump P.
  • Page 375 Operation 5.11.4.1 Sponge balls and other accessories Figure 169: Cleaning accessories Item Designation Sponge pig Sponge cube Sponge ball Wash-out pig You will need sufficient numbers of sponge balls and other clean‐ ing accessories to clean the machine properly. 5.11.4.2 Catch basket The use of the catch basket is recommended when water is used to force out the concrete, to ensure that the delivery line is sealed...
  • Page 376 Operation Figure 170: Fitted catch basket Item Designation Coupling Catch basket (closed pipe section) Spring pin (on both sides) Catch bracket (2) when pushing concrete out “towards the 1. Use the catch basket front” using compressed air or water. 2. Ensure that the concrete can flow out unobstructed, while at the same time the sponge ball (cube, pig) can be caught and thereby the delivery line sealed towards the rear.
  • Page 377 Operation 5.11.4.3 Wash-out adaptor The wash-out adaptor is used when the machine is cleaned using pressurized water or compressed air. Figure 171: Wash-out adaptor structure Item Designation Pressure gauge Guard bracket Connection for pressurized water or compressed air Shut-off valve for connection Pressure dump elbow Dump cock 5 —...
  • Page 378 Operation 5.11.4.4 Cement bags for cleaning with pressurized water Cement bags soaked in water and rolled up have proved useful when cleaning the delivery line using water under pressure. The cement bags prevent the washing water entering into the concrete, rinsing it out and causing a blockage.
  • Page 379 Operation Figure 174: Cleaning in the hopper Item Designation Adhesive tape marking 1. Measure the hose length required on the outside of the transfer tube. The hose spray nozzle should be located just in front of the wear ring, so that concrete residue is washed out of the area of the wear ring and seal ring when the spray is set.
  • Page 380 Operation 5.11.5.1 Overview of the cleaning methods On the following page you will find an overview showing which clean‐ ing method is recommended for the delivery lines listed. The symbols used in the overview are explained below. The cleaning procedures are described in the following sections.
  • Page 381 Operation Prohibited method of cleaning Method of cleaning not possible Overview of the cleaning methods Truck-mounted concrete pump Delivery line Concrete res‐ idue / type of cleaning Boom delivery Compressed only with special line: equipment no onwards de‐ Water under livery line con‐...
  • Page 382 Operation Stationary delivery line Delivery line Concrete resi‐ due / type of cleaning Riser Compressed only with spe‐ cial equipment Water under pressure Suction clean‐ Downpipe Compressed only with spe‐ cial equipment Water under pressure Suction clean‐ 5.11.5.2 Suction cleaning Suction cleaning is the simplest and least hazardous method of cleaning.
  • Page 383 Operation Insert the wash-out sponge Figure 175: Inserting a water-soaked wash-out sponge ▶ Insert a water-soaked wash-out sponge (cube) into the end hose outlet. 5 — 137 210110691_2018-09-19_EN Operating Instructions...
  • Page 384 Operation Move the placing boom to a rising position Figure 176: Placing boom in rising position ▶ Shift the placing boom into a uniformly rising position. ⇒ Reverse pumping of the concrete is made easier because the concrete flows backwards due to its self-weight. Reverse pumping the concrete WARNING Risk of injury...
  • Page 385 Operation Figure 177: Button “Switch reverse pumping on/off” Item Designation Button “Switch reverse pumping on/off”. ▶ Switch the core pump to reverse pumping. ⇒ The concrete and the wash-out sponge are pumped back through the delivery line. 5 — 139 210110691_2018-09-19_EN Operating Instructions...
  • Page 386 Operation Tracking the wash-out sponge Figure 178: Tapping the delivery line with a hammer handle 1. Tap on the delivery line with a piece of hardwood (hammer han‐ dle) just ahead of the cleaning port during the washing out proc‐ ess.
  • Page 387 Operation Trapping the wash-out sponge Figure 179: Pushing the pin on the wash-out port lid into the delivery line 1. Unlock the movable pin on the wash-out port lid and push it into the delivery line. 2. Switch the core pump back to reverse pumping. ⇒...
  • Page 388 5.11.6.1 Draining concrete residue Figure 180: Lay the sheet down 1. Place the Putzmeister concrete residue sheet under the hopper. 2. Open the slide gate beneath the hopper and let the concrete resi‐ due flow out of the hopper. 3. Switch the pump over to reverse pumping.
  • Page 389 Figure 181: Hoisting the concrete away You may only hoist a maximum of 0.5 m of concrete (approx. 1200 kg) using the Putzmeister concrete residue sheet. 4. Hoist away the concrete in the concrete residue sheet. 5.11.6.2 Spraying out the delivery cylinder Prerequisites: Take note of the warning notice at the beginning of the “Cleaning”...
  • Page 390 Operation Figure 182: Spray out the transfer tube valve and delivery cylinder in cases where the concrete pump is running backwards slowly 1. Open the hinged elbow . 2. Allow the concrete pump to run slowly in reverse. 3. Spray the transfer tube out carefully downwards from the hinged elbow.
  • Page 391 Operation 5.11.6.3 Cleaning the gap between the transfer tube bearing and the transfer tube After each pumping operation, you must clean the transfer tube bear‐ ing thoroughly to prevent any concrete encrustation in the transfer tube bearing. Figure 184: Example illustration of cleaning the transfer tube bearing Item Designation S transfer tube...
  • Page 392 Operation Item Designation Lubrication points Hinged elbow (6) . 1. Open the hinged elbow (3) . 2. Remove the square section seal ring (4) of the transfer 3. Carefully spray out the surfaces to be cleaned (2) . tube bearing 4.
  • Page 393 Operation 5.11.6.4 Closing the hinged elbow Figure 185: Hinged elbow lock Item Designation Lettering “0” or milling Retaining bolt for hinged elbow Milling for recognizing the correct mounting position. Hinged elbow Wedge Tie rod for retaining bolt Spring pin 5 — 147 210110691_2018-09-19_EN Operating Instructions...
  • Page 394 Operation (2) must be screwed onto the tie rod (6) as The retaining bolt (1) upwards). On‐ shown in the figure above (lettering “0” or milling (5) be used for locking the hinged el‐ ly in this way can the chock bow.
  • Page 395 Operation NOTICE Frost damage Possible damage to the delivery line, water box, water tank and wa‐ ter pumps (if they are not emptied) when there is a risk of freezing. 1. Empty the water box, even at normal temperatures, during lengthy breaks in pumping (overnight, at the weekend, etc.).

  • Page 396: Driving

    Operation 5.12 Driving position 5.12.1 Shifting the placing boom to the driving position The following section describes how the placing boom is folded with full support and then with limited support, as an example. NOTICE Material damage ▶ Follow the instructions for raising and lowering the placing boom.
  • Page 397 Operation After you have switched the power takeoff to “driving”, the placing boom is checked to ensure that it is in the driving position. An acoustic warning signal sounds in the driver's cab if the placing boom is not in the driving position. The acoustic warning signal no longer sounds if the boom cradle switch has been activated.
  • Page 398 Operation Figure 187: Folding Arm 4 in fully 2. Fold Arm 4 fully. ⇒ Arm 4 is resting against Arm 3. Figure 188: Folding Arm 5 in fully 3. Fold Arm 5 fully. ⇒ Arm 5 is resting against Arm 4. 5 —...
  • Page 399 Operation Figure 189: Folding Arm 3 in fully 4. Fold Arm 3 fully. ⇒ Arm 3 is resting against Arm 2. Figure 190: Folding Arm 2 and catching the end hose 5. Fold Arm 2. ⇒ The end hose automatically drops into the transport latches. 5 —...
  • Page 400 Operation Figure 191: Slewing the placing boom and lowering it onto the boom cradle 6. Slew the placing boom into the storage position. 7. Place the placing boom on the boom cradle. 8. Check that the end hose is secured for transport. 5.12.1.2 Folding the placing boom with limited support This section describes moving the placing boom out of the working...
  • Page 401 Operation If the placing boom is located in the working area, move the placing boom into the driving position as follows: 1. Fold in all arms which are inside the working area. 2. Slew the placing boom toward the boom cradle. 3.
  • Page 402 Operation 5.12.3 Remote control Figure 193: Operating mode selector switch Information regarding the working area, support variant, gradient of the machine, raise monitoring and faults can be found on the re‐ mote control in the “Support” menu and its “Spirit level” submenu. You must first switch on the support functions before you can support the machine.
  • Page 403 Operation 2. Remove the spring pins on all snaplocks. 3. Retract the rear support feet. 4. Retract the forward support feet. 5. Open the snaplocks. 6. Retract the telescopic support legs. 7. Swing the swinging support legs in. ⇒ The snaplocks lock the support legs automatically as soon as they have reached the end position for the machine to be ready to drive.
  • Page 404 Interrupting this run-down time will cause a fault in the control unit. This fault is shown continuously in the display, which means that you run the risk of overlooking other faults. Putzmeister will not ac‐ cept warranty claims for engine damage and operating errors that result from a failure to switch off the engine according to the instruc‐...
  • Page 405 Operation ▶ See above for instructions on how to switch off DEUTZ engines with an EMR3 electronic engine governor. 5. Check the battery’s state of charge. ▶ Charge the battery if required. 6. Connect the central control unit (CCU) to a supply voltage at six- monthly intervals.
  • Page 406 Operation 2. Close the spray guard. 3. Spray the hopper area with barrier agent. 5.14.9 General measures to preserve the value of the truck superstructure assembly ▶ Grease all exposed piston rods with Vaseline. 5 — 160 Operating Instructions 210110691_2018-09-19_EN...
  • Page 407 Glossary This chapter illustrates the control system symbols (icons for concrete pumps) and explains the abbreviations and technical terms that are used in Putzmeister Operating Instructions. B — 1 210110691_2018-09-19_EN Operating Instructions...
  • Page 408 B — 2 Operating Instructions 210110691_2018-09-19_EN...
  • Page 409 Glossary Symbols for concrete pumps in accordance with German Mechanical Engineering Association Standard (VDMA -24119) 3701 3713 3725 5008 6012 7005 3702 3714 4001 6001 6013 7006 3703 3715 4002 6002 6014 7007 3704 3716 4003 6003 6015 7008 3705 3717 4004 6004...
  • Page 410 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 411 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 Figure 196: “General” symbols 3 Symbols key: General Item Designation...
  • Page 412 Glossary Item Designation 3716 Pump control system 3717 Changeover 3718 Stroke pulse for change-over 3719 Stroke correction 3720 Change-over delay 3721 Screw conveyor 1 anticlockwise rotation 3722 Screw conveyor 1 clockwise rotation 3723 Screw conveyor 2 anticlockwise rotation 3724 Screw conveyor 2 clockwise rotation 3725 Screw conveyor 4001...
  • Page 413 Glossary Item Designation 6012 High pressure 6013 Accumulator pressure 6014 Filter element 6015 Rod side 6016 Piston side 6017 Hydraulic fluid filter water level stop (PM symbol) 6018 Hydraulic fluid filter water level warning (PM symbol) 6019 Hydraulic fluid filter contamination warning (PM symbol) 7001 Spotlights 7002...
  • Page 414 Glossary Item Designation 10002 Diesel engine Off 10003 Engine oil excess temperature 10004 Cooling water excess temperature 10005 Acknowledge cooling water excess temperature 10006 Engine oil pressure 10007 V-belt failure 10008 Increase speed, reduce speed 10009 Speed 10010 Speed sensor 10011 Increase speed 10012...
  • Page 415 Glossary Item Designation 12007 Acknowledge EMERGENCY STOP 12008 Stop 12009 Test run 12010 Vibrator On 12011 Vibrator Off 12012 Vibrator 12013 Potentiometer 12014 Off - On 12015 12016 12017 Fast (e.g. acceleration) 12018 Normal (e.g. acceleration) 12019 Compressor 12020 Compressor on - off 12021 Motor vehicle fuse 12022...
  • Page 416 Glossary Item Designation 12040 Container 12041 Position at the machine 12042 Lock 12043 2nd level 12044 Circuit 1 12045 Circuit 2 12046 Circuits 1+2 12047 High-pressure limit 12048 Flap/closure closed 12049 Flap/closure open 12050 Generator 12051 Boom on cradle 12052 Manual operation 12053 Electrical levelling...
  • Page 417 Glossary 2601 2604 2607 2610 2613 2616 2602 2605 2608 2611 2614 2617 2603 2606 2609 2612 2615 Figure 197: “Support” symbols Symbols key: Support Item Designation 2601 Retract/extend support leg/foot 2602 Extend support leg 2603 Retract support leg 2604 Lower support foot 2605 Raise support foot...
  • Page 418 Glossary 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 Figure 198: Symbols for “Boom with five arms” Symbols key: Boom with five arms Item Designation 1501...
  • Page 419 Glossary Item Designation 1518 Slew boom to the left switched off 1519 Slew boom to the right switched off 1520 Arm 1 down switched off 1521 Arms up switched on 1522 Tilt switch, Arm 1 circuit 1 1523 Tilt switch, Arm 1 circuit 2 1524 Tilt switch, Arm 2 circuit 1 1525...
  • Page 420 Glossary Item Designation 1504 End hose up 1505 End hose down 1506 Unfold placing boom 1506A Unfold placing boom (USA) 1507 Fold placing boom 1507A Fold placing boom (USA) 1508 End hose to the left 1509 End hose to the right 1410 Upper limit 1411...
  • Page 421 Glossary Automatic Piston Pull A ball valve is installed in the drive cylinder. When the ball cock is closed, you can pull the delivery piston out of the delivery cylinder to replace it. Blockage Blockage in the delivery line: The concrete behind the blockage cannot continue to flow.
  • Page 422 (Ergonic Output Control P. B — 17) (Ergonic Pump System P. B — 17) Ergonic ® Registered brand name for all Putzmeister components which control concrete pumps and plac‐ ing booms. B — 16 Operating Instructions 210110691_2018-09-19_EN...
  • Page 423 Glossary Ergonic Boom Control Microprocessor supported system for controlling and regulating the placing boom. Among other func‐ tions, EBC allows you to move the placing boom using just one joy‐ stick. Ergonic Graphic Display - Re‐ Graphic display in the remote con‐ mote Control trol.
  • Page 424 Glossary cylinder, i.e fluid flows freely with‐ (Free-Flow out interposing valves Hydraulics (FFH) P. B — 17) . Fully hydraulic control system The fully hydraulic control system (VHS) controls the concrete pump by switching the fluid flow from the main pump to the drive cylinder by means of valves (closed, non-pre‐...
  • Page 425 ● NA is a transmission-depend‐ ent power take-off. ● NMV is a power take-off inde‐ pendent of the clutch. Operating equipment Battery, filters PEDOC Putzmeister Electronic Documen‐ tation (Putzmeister Electronic Documen‐ tation P. B — 20) B — 19 210110691_2018-09-19_EN Operating Instructions...
  • Page 426 Proportional control Infinite boom speed control Putzmeister Electronic Docu‐ Documentation accompanying the mentation machine on CDROM Reversal The concrete is sucked back from the delivery line into the hopper.
  • Page 427 Glossary RZ folding system Roll-Z folding system Type of folding of the placing boom: The placing boom is “rolled ”during folding and unfolding; however, the last two arms are folded and unfolded in a Z shape. Service operation Use the “Pumping operation-Serv‐ ice operation”...
  • Page 428 Glossary Squeeze valve The squeeze valve is a component on the end hose which closes the delivery line when the pump is stopped. Stroke correction The stroke is corrected automati‐ cally by the addition or removal of hydraulic fluid through bores in the drive cylinders.
  • Page 429 Glossary ● Machine gradient and distortion ● Locked areas near to and above the driver’s cab (ma‐ chine-specific) Teach-in Specialist word for storing in mem‐ Test reading The measurement record is part of the documentation accompanying the machine: List of the machine setting values Tilting edge The tilting edge surrounds the ma‐...
  • Page 430 B — 24 Operating Instructions 210110691_2018-09-19_EN...
  • Page 431 Index Index In this chapter, you will find the most important keywords and the number(s) of the page(s) on which they appear. This index of key words is in alphabetical order.  P. 2 — 21 Before working with the machine  P.
  • Page 432 Index  P. 3 — 50 Button “Working light in pump area On/Off” Cleaning the gap between the transfer tube bearing and  P. 5 — 145 the transfer tube   Cleaning the hopper, delivery cylinder and transfer tube P. 5 — 141  P.
  • Page 433 Index  P. 5 — 105  P. 3 — 5 Dangers during pumping operations Electromagnetic compatibility (EMC)  P. 2 — 9, 5 — 21, 5 — 69  P. 5 — 41 Danger zone Electronic spirit level  P. 3 — 8  P. 3 — 71 Data for the delivery line on the placing boom Electronic spirit level - colour definitions  P.
  • Page 434 Index   Filling the lubricant reservoir using a grease gun General measures to preserve the value of the placing P. 5 — 19  P. 5 — 159 boom assembly  P. 5 — 103, 5 — 104 Filling the water box General measures to preserve the value of the truck su‐...
  • Page 435 Index  P. 4 — 7, 5 — 90  P. 5 — 107 Hand signal for stopping Incorrect use of the end hose  P. 5 — 102   Hand signal for stopping the pump Independent retracting of the hydraulic cylinders P. 5 — 73  P.
  • Page 436 Index    P. 3 — 65 “Limit individual arms and slewing gear” menu Menu ribbon P. 3 — 77  P. 3 — 63 Menu structure  P. 3 — 89 “Limit output” menu  P. 3 — 138 Method of operation  P. 2 — 32, 4 — 11 Loading  P.
  • Page 437 Index  P. 5 — 1  P. 3 — 140 Operation Pump control system  P. 2 — 4  P. 3 — 9 Operator Pump delivery line data  P. 3 — 143  P. 3 — 86 Other components “Pump info” menu  P. 2 — 19  P.
  • Page 438 Index  P. 5 — 156  P. 3 — 9, 3 — 10 Retracting the supports Sound power level  P. 3 — 26  P. 3 — 9, 3 — 10 Reversal Sound pressure level  P. 5 — 138  P. 3 — 9 Reverse pumping the concrete Sound pressure level/sound power level  P.
  • Page 439  P. 6 — 12 Symbols key: Boom with five arms “User-defined boom speed for single-axis operation” Symbols key: Ergonic Boom Control with five arms –  P. 3 — 82 menu  P. 6 — 13 other Putzmeister symbols C — 9 210110691_2018-09-19_EN Operating Instructions...
  • Page 440 Index  P. 3 — 105 “User settings – machine” menu  P. 3 — 106 “User settings – remote control” menu  P. 5 — 121 Using concrete residue with a wheelbarrow   Using concrete residue with concrete residue sheet P. 5 — 120  P.
  • Page 441 Translation of the original instructions Truck-mounted concrete pump BSF 47-5.16 H Machine no. 210110691 2018-09-19 The paper on which this document is printed is 100% chlorine-free © Putzmeister Concrete Pumps GmbH 2018...
  • Page 442 Britain Carrwood Road GB−Chesterfield +44−1246−26 00 77 PMUK www.putzmeister.co.uk Derbyshire S41 9QB Türkiye +90−282−735−1000 Putzmeister Makine Sanayi ve Tic. A. pm@putzmeister.com.tr G.O. Pa a Mah. Nam k Kemal Bulvar No: 6 +90−282−738−1001 www.putzmeister.com.tr 59500 Çerkezköy / TEK +1−262−886−3200 Putzmeister America pmr@putzam.com...
  • Page 443 Translation of the original instructions ‫الأصلي‬ ‫التشغيل‬ ‫دليل‬ ‫ترجمة‬ Превод на оригиналното „Ръководство за работа“ Překlad originálního návodu k obsluze Oversættelse af den originale driftsvejledning Übersetzung der Originalbetriebsanleitung Μετάφραση του πρωτότυπου των οδηγιών λειτουργίας Traducción del manual de instrucciones original Originaalkasutusjuhendi tõlge Alkuperäisen käyttöohjeen käännös Traduction de la notice originale...
  • Page 444 Operating Instructions EBC 210110691_2018-09-19_EN...
  • Page 445 Table of contents . . . Table of contents Guide to the Operating Instructions ........1 — 1 Foreword ......................... 1 — 3 Icons and symbols ......................1 — 4 1.2.1 Layout of warning notices ....................1 — 5 Safety regulations ..............2 —...
  • Page 446 Table of contents . . . 4.4.1 Set upper limit ......................... 4 — 17 4.4.2 Set lower limit ........................4 — 18 4.4.3 Move the end hose within the limits ................4 — 20 4.4.4 Setting the limits for individual arms or the slewing gear ..........4 —...
  • Page 447 In this chapter you will find notes and information that will help you use these Operating Instructions. If you have any queries, please write to us in confidence at the address given below, or contact the relevant branch or works agency. Putzmeister Concrete Pumps Abteilung Kundendienst Max-Eyth-Straße 10 72631 Aichtal, Germany...
  • Page 448 1 — 2 Operating Instructions EBC 210110691_2018-09-19_EN...

  • Page 449: Guide To The Operating Instructions

    Guide to the Operating Instructions Foreword These Operating Instructions refer solely to the EBC functions. is a registered brand name for all Putzmeister com‐ ponents which control concrete pumps and placing booms. These Operating Instructions aim to help you to familiarise yourself with the EBC functions and make use of their intended applications.

  • Page 450: Icons And Symbols

    Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utili‐ ty model or design. © Putzmeister Concrete Pumps GmbH 1994 Icons and symbols The following icons and symbols are used:...

  • Page 451: Layout Of Warning Notices

    Guide to the Operating Instructions Icon/symbol/ Meaning designation Link/cross ref‐ A link/cross reference to related topics. Cross ref‐ erence: erence with page number and heading. If the cross reference is displayed digitally, it acts as a (Icons and direct link to a related topic area. symbols P.
  • Page 452 Guide to the Operating Instructions DANGER Indicates a dangerous situation in which an accident resulting in se‐ rious injuries and/or death may occur. Highest level of risk. ▶ After identifying the risk, instructions are set out which are inten‐ ded to avoid or remedy the risk. WARNING Indicates a dangerous situation in which an accident resulting in se‐...
  • Page 453 Safety regulations This chapter summarises the most important safety regulations. This chapter is therefore particularly useful for providing initial and basic instruction for new employees. The individual rules and regulations can of course also be found in the relevant parts of the Operating In‐ structions as well.
  • Page 454 2 — 2 Operating Instructions EBC 210110691_2018-09-19_EN...

  • Page 455: Safety Regulations

    Safety regulations Basic principle The safety regulations in the Operating Instructions for this machine apply whenever the machine is operated. The machine may only be operated with the EBC control system if this is functioning correctly. Designated use The EBC control system is a semi-automatic operating device for the placing boom.

  • Page 456: Defective Ebc Components

    2.3.3 Exclusion of liability We state here expressly that Putzmeister accepts no liability for dam‐ age arising from incorrect or negligent operation, servicing or mainte‐ nance or as a result of use contrary to the designated use. This state‐...
  • Page 457 General technical description This chapter describes the Ergonic operating elements and explains how they function. Please note that possible (optional) additional equipment is also described. Refer to the machine card to check whether you have the particular additional equipment or not. 3 —...
  • Page 458 3 — 2 Operating Instructions EBC 210110691_2018-09-19_EN...

  • Page 459: General Technical Description

    General technical description What is EBC? EBC (Ergonic Boom Control) is a computer-aided control system used to control the placing boom. Among other functions, EBC allows you to move the placing boom using just one . The EBC func‐ JOYSTICK tions include: ●...

  • Page 460: What Does Ebc Comprise

    General technical description 3.1.2 What does EBC comprise? Figure 1: Setup of EBC components Item Designation Central control cabinet Radio base station “Remote control” mobile control unit Operating mode selector switch Remote control cable for cable operation (optional use) 3.1.3 Kits Certain functions are only available with the following kits.

  • Page 461: Remote Control

    General technical description Additional functions EBC Basis Moving the end hose (“Coupled driving” oper‐ ating mode) Unfolding aid for the placing boom Specifying speeds for individual arms Boom damping Folding assistance with automatic lowering of the placing boom EBC Plus All EBC Basis functions Specifying placing boom speeds for directions (vertical, horizontal, slewing)
  • Page 462 General technical description Figure 2: Organisation of the operating mode selector switch Item Designation Switch position 1: “Support leg control” Switch position 2: “0” or switch position when the remote control is switched on Switch position 3: “Single axis regulated driving” Switch position 4: “Coupled driving”...

  • Page 463: Boom Control Symbols

    General technical description Switch po‐ Symbol Description sition Single-axis regulated driving (EBC) ● Move individual arms with boom damping ● Self-collision is taken into account ● Working range limits are taken into account Coupled driving (EBC) ● Move the entire placing boom with boom damping ●...
  • Page 464 General technical description Colour Function/meaning Black Every machine features this “section” of the placing boom. Green Whether this “section” of the placing boom is present is determined by the number of arms. These functions are EBC functions. 3.2.2 Joysticks WARNING Risk of injury from unintended movement of the placing boom Simultaneous operation of the and a...
  • Page 465 General technical description Symbol Function/meaning Black: Raise last arm Red: Fold automatically Black: Lower last arm Red: Unfold automatically Green: Raise second-to-last arm Green: Lower second-to-last arm Green: Raise third-to-last arm Green: Lower third-to-last arm 3.2.2.2 Righthand joystick The first two arms and slewing gear are moved using the right-hand joystick.
  • Page 466 General technical description Symbol Function/meaning Black: Raise Arm 1 Red: Retract the end hose completely Black: Lower Arm 1 Red: Move the end hose fully forwards Green: Raise Arm 3 (only on placing booms with six arms) Black: Raise Arm 2 Red: Raise the end hose completely Green: Lower Arm 3 (only on placing booms with six arms)

  • Page 467: Set Limits" Menu (Ebc Plus)

    General technical description 3.2.4 “Set limits” menu (EBC Plus) The “Set limits” menu is an initial menu that can be used to set the spatial limits for the individual arms and the entire placing boom. WARNING Risk of injury from unintended movement of the placing boom Simultaneous operation of the and a OPERATING MODE SELECTOR SWITCH...
  • Page 468 General technical description Function Symbol Description button “Upper and lower limit setting” menu (“Upper and lower limit setting” menu P. 3 — 12) Red lock: Limits set Green lock: No limits set Delete all set limits “Limit individual arms and slewing gear” menu (see Operating Instructions) Red lock: Limits set Green lock: No limits set...
  • Page 469 General technical description The “Upper and lower limit setting” menu and the associated func‐ tions can only be used in conjunction with the EBC function. The boom limits are set in this menu at the touch of a button based on the position of the boom tip.
  • Page 470 General technical description The “Set upper limit for arm” and “Set lower limit for arm” functions in the “Limit individual arms and slewing gear” menu can only be used in conjunction with the EBC function. The two last arms of the placing boom cannot be limited, as other‐ wise the placing boom can no longer be used.

  • Page 471: Select Boom Speed" Menu

    General technical description The colours of the fields have the following meanings: Colour Function/meaning Green The arm or slewing gear is not limited. The arm or slewing gear is limited. Flashing yellow The arm or slewing gear is selected. Figure 4: Upper and lower limits set but arm can still move If the arm is moved between setting the upper limit and setting the lower limit, the arm can be moved within these two limits.
  • Page 472 General technical description The “Select boom speed” menu and associated functions can be used with or without the EBC function (in switch position 3 “Single-ax‐ is regulated driving”, switch position 4 “Coupled driving” and switch position 6 “Single-axis unregulated driving”). Figure 5: Organisation of the operating mode selector switch Item Designation...
  • Page 473 General technical description Function Symbol Description button “User-defined boom speed for single-ax‐ is operation” menu (“User-defined boom speed for single-ax‐ is operation” menu P. 3 — 18) “User-defined boom speed for coupled operation (EBC Plus)” menu (“User-defined boom speed for coupled operation (EBC Plus)”...

  • Page 474: User-Defined Boom Speed For Single-Axis Operation" Menu

    General technical description Status dis‐ Symbol Description play Boom The “slow” boom speed is activated speed The “fast” boom speed is activated The “user-defined” boom speed is activa‐ 3.2.6 “User-defined boom speed for single-axis operation” menu You can set the speeds for the individual axes of the placing boom in the “User-defined boom speed for single-axis operation”...

  • Page 475: User-Defined Boom Speed For Coupled Operation (Ebc Plus)" Menu

    General technical description Function Symbol Description button Select axis Reduce the speed of the selected axis Reset the speed of the selected axis to the standard value Save setting Increase the speed of the selected axis 3.2.7 “User-defined boom speed for coupled operation (EBC Plus)” menu You can set and store the speeds for the directions of movement of the end hose in the “User-defined boom speed for coupled operation”...
  • Page 476 General technical description Function Symbol Description button Select axis Reduce the speed of the selected axis Reset the speed of the selected axis to the standard value Save setting Increase the speed of the selected axis Status dis‐ Symbol Description play Selected di‐...
  • Page 477 Operating the EBC This chapter contains information regarding the operation of the ma‐ chine with Ergonic Boom Control. The procedures described in the Operating Instructions for the machine are also valid in addition to the procedures described in these Operating Instructions. 4 —...
  • Page 478 4 — 2 Operating Instructions EBC 210110691_2018-09-19_EN...

  • Page 479: Operating The Ebc

    Operating the EBC Switching on the Ergonic Boom Control The procedures listed below must be observed when starting up the machine with EBC. WARNING Risk of injury from the placing boom moving unexpectedly if the EBC control system is not operated correctly The placing boom may move unexpectedly as a result of the Ergon‐...

  • Page 480: Folding And Unfolding The Placing Boom

    Operating the EBC Item Designation Operating mode selector switch Remote control cable for cable operation (optional use) 1. Switch the to “0”. OPERATING MODE SELECTOR SWITCH 2. Turn the STOP BUTTON ⇒ You have unlocked the STOP button. 3. Press the “Deactivate EMERGENCY STOP” twice, holding BUTTON it down for a longer period the second time.
  • Page 481 Operating the EBC WARNING Risk of injury from a dangling end hose Depending on the machine equipment, the end hose may be lying loose in the end hose retainer. The end hose dangles when the placing boom is being extended and folded. ▶...

  • Page 482: Unfold Placing Boom

    Operating the EBC Only the arms are controlled during semi-automatic folding and un‐ folding of the placing boom. You have to control the slewing gear yourself. ▶ Switch the to “Semi-automatic OPERATING MODE SELECTOR SWITCH folding/unfolding”. 4.2.1 Unfold placing boom Prerequisites: ✓...
  • Page 483 Operating the EBC 1. Push the left away from you. JOYSTICK ⇒ The placing boom will continue to unfold for as long as you keep pushing the JOYSTICK Do you have to interrupt the unfolding program in order to move an arm individually? 1.
  • Page 484 Operating the EBC ⇒ The unfolding program can be restarted. 4.2.1.3 Example showing individual stages in the semi-automatic extending of the RZ placing boom as far as the end position The RZ placing boom end position means: ● Arm 1 remains in the position to which you move it. ●...
  • Page 485 Operating the EBC Figure 7: Individual stages of extending 4 — 9 210110691_2018-09-19_EN Operating Instructions EBC...

  • Page 486: Fold Placing Boom

    Operating the EBC 4.2.2 Fold placing boom NOTICE Damage caused by concrete in the delivery line When the placing boom is being folded, the arm is moved to posi‐ tions that would place too heavy a load on the placing boom with a full delivery line.
  • Page 487 Operating the EBC 4.2.2.1 Starting the folding program 1. Pull the left-hand JOYSTICK ⇒ The placing boom will continue to fold for as long as you keep pulling the joystick. While the automatic folding program is active and the slewing gear is automatically positioned above the boom cradle, you can over‐...
  • Page 488 Operating the EBC The placing boom stops suddenly? You have started the semiautomatic folding program from an inap‐ propriate placing boom position. The placing boom stops because one arm would otherwise collide with another arm. 1. Switch the to “Single-axis regu‐ OPERATING MODE SELECTOR SWITCH lated driving”.
  • Page 489 Operating the EBC 4.2.2.3 Example showing individual stages in the semi-automatic folding of the placing boom Figure 8: Individual stages of folding 4 — 13 210110691_2018-09-19_EN Operating Instructions EBC...

  • Page 490: Moving The End Hose

    Operating the EBC 4.2.2.4 Positioning the placing boom on its support Figure 9: Slewing the placing boom and lowering it onto the boom cradle The individual arms are kept together during setting down of the plac‐ ing boom. This prevents the placing boom from sinking and possibly causing damage to the boom cradle.

  • Page 491: Upper And Lower Limit Setting

    Operating the EBC Figure 10: Moving the end hose using the right-hand joystick 2. Move the end hose using the RIGHT HAND JOYSTICK Upper and lower limit setting You can set an upper and lower limit for the placing boom to prevent the placing boom from touching the ceiling or floor when concreting in low buildings, for example.
  • Page 492 Operating the EBC NOTICE Damage caused by collision with obstacles The set limits are only monitored if the OPERATING MODE SELECTOR is switched to switch position 3 – “Single-axis regulated driv‐ SWITCH ing” or to switch position 4 – “EBC-coupled driving”. ▶...

  • Page 493: Set Upper Limit

    Operating the EBC Figure 11: Starting position 3. Move the placing boom to its starting position. 4. Switch the to “Single-axis regula‐ OPERATING MODE SELECTOR SWITCH ted driving” or “Coupled driving”. Figure 12: “Upper and lower limit setting” menu 5. Switch to the “Upper and lower limit setting” menu. 4.4.1 Set upper limit Prerequisites:...

  • Page 494: Set Lower Limit

    Operating the EBC Figure 13: Set upper limit Item Designation Upper limit 1. Move the boom tip until it is approx. 0.2 m below the hall ceiling. 2. Press F2. ⇒ The upper limit is set. ⇒ The “lock” symbol becomes red. 4.4.2 Set lower limit Prerequisites:...
  • Page 495 Operating the EBC Figure 14: Upper and lower limits Item Designation Upper limit Lower limit 1. Move the boom tip until it is approx. 0.2 m above the ground. Figure 15: Set lower limit 2. Press F3. ⇒ The limit is saved. ⇒...

  • Page 496: Move The End Hose Within The Limits

    Operating the EBC 4.4.3 Move the end hose within the limits Prerequisites: (Up‐ Take note of the warning notice at the beginning of this section per and lower limit setting P. 4 — 15) . Figure 16: Dangling end hose – placing boom in starting position 1.

  • Page 497: Setting The Limits For Individual Arms Or The Slewing Gear

    Operating the EBC ⇒ The arms only move within the corridor of the upper and lower limits. Figure 18: Arm movement within the set limits The lower and upper limits are also monitored in switch position 3 – “Single-axis regulated driving”. 4.4.4 Setting the limits for individual arms or the slewing gear In order to prevent collision with obstacles on a construction site, you...
  • Page 498 Operating the EBC Figure 19: Example of Arm 1 and Arm 2 in the ideal positions 1. Unfold the placing boom so that Arm 1 and Arm 2 adopt the per‐ missible position that you want them to occupy. Figure 20: Setting the limits for individual arms or the slewing gear 2.
  • Page 499 Operating the EBC Figure 21: Select the lower limit 4. Press and hold the F2 until the column for Arm 2 is selec‐ BUTTON ted (see arrow). ⇒ The column for Arm 2 will flash yellow. Figure 22: Lower limit, Arms 1 and 2 5.

  • Page 500: Deleting Limits

    Operating the EBC Arm 1 and Arm 2 cannot be moved any further downwards, but can be moved upwards freely. All other arms can be moved as de‐ sired. You can set further limits, as described above. 4.4.5 Deleting limits (Upper and Take note of the warning notices at the beginning of the lower limit setting P.
  • Page 501 Operating the EBC Figure 24: Example 2 – Delete limits for Arm 1 2. Press the F4 to delete both limits at the same time. BUTTON Figure 25: Example 3 – Delete both limits 3. Press the F4 to delete both limits at the same time. BUTTON 4 —...

  • Page 502: Boom Damping

    Operating the EBC Boom damping A placing boom may bounce as a result of the boom position or the delivery rate. This can cause the following problems: ● The hoseman can no longer guide the end hose. ● The concrete splashes. ●...

  • Page 503: Index

    Index Index In this chapter, you will find the most important keywords and the number(s) of the page(s) on which they appear. This index of key words is in alphabetical order.  P. 4 — 26  P. 2 — 3 Activating boom damping High-voltage lines  P.
  • Page 504 Index  P. 3 — 9 Righthand joystick  P. 2 — 1 Safety regulations  P. 3 — 15 “Select boom speed” menu Selection area: Limiting individual arms and the slewing  P. 3 — 14 gear – colour settings  P. 3 — 11 “Set limits”...
  • Page 505 Translation of the original instructions Truck-mounted concrete pump BSF 47-5.16 H Machine no. 210110691 2018-09-19 The paper on which this document is printed is 100% chlorine-free © Putzmeister Concrete Pumps GmbH 2018...
  • Page 506 Britain Carrwood Road GB−Chesterfield +44−1246−26 00 77 PMUK www.putzmeister.co.uk Derbyshire S41 9QB Türkiye +90−282−735−1000 Putzmeister Makine Sanayi ve Tic. A. pm@putzmeister.com.tr G.O. Pa a Mah. Nam k Kemal Bulvar No: 6 +90−282−738−1001 www.putzmeister.com.tr 59500 Çerkezköy / TEK +1−262−886−3200 Putzmeister America pmr@putzam.com...
  • Page 507 Translation of the original instructions ‫الأصلي‬ ‫التشغيل‬ ‫دليل‬ ‫ترجمة‬ Превод на оригиналното „Ръководство за работа“ Překlad originálního návodu k obsluze Oversættelse af den originale driftsvejledning Übersetzung der Originalbetriebsanleitung Μετάφραση του πρωτότυπου των οδηγιών λειτουργίας Traducción del manual de instrucciones original Originaalkasutusjuhendi tõlge Alkuperäisen käyttöohjeen käännös Traduction de la notice originale...
  • Page 508 Service Instructions 210110691_2018-09-19_EN...
  • Page 509 Table of contents . . . Table of contents Guide to the Service Instructions ..........1 — 1 Foreword ......................... 1 — 3 Icons and symbols ......................1 — 4 1.2.1 Layout of warning notices ....................1 — 5 Safety regulations ..............2 —...
  • Page 510 Table of contents . . . 3.1.5 Safety components ......................3 — 6 3.1.6 Parts with increased maintenance requirements ............3 — 6 EMERGENCY STOP ...................... 3 — 7 3.2.1 Description of the functions ..................... 3 — 7 3.2.2 Function check ........................ 3 —...
  • Page 511 Table of contents . . . 4.3.1 Emergency operation of the agitator ................4 — 7 4.3.2 Emergency operation of the flushing water pump ............4 — 7 4.3.3 Emergency operation of the high-pressure water pump ..........4 — 8 Process monitoring mode 2 ....................
  • Page 512 Table of contents . . . 5.7.8 Core pump ........................5 — 63 5.7.9 Delivery line ........................5 — 131 5.7.10 Slewing head ........................5 — 150 Index ..................C — 1 A — 4 Service Instructions 210110691_2018-09-19_EN...
  • Page 513 In this chapter you will find notes and information that will help you use these Service Instructions. If you have any queries, please write to us in confidence at the address given below, or contact the relevant branch or works agency. Putzmeister Concrete Pumps Abteilung Kundendienst Max-Eyth-Straße 10 72631 Aichtal, Germany...
  • Page 514 1 — 2 Service Instructions 210110691_2018-09-19_EN...

  • Page 515: Guide To The Service Instructions

    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 na‐...

  • Page 516: Icons And Symbols

    Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utili‐ ty model or design. © Putzmeister Concrete Pumps GmbH 1994 Icons and symbols The following icons and symbols are used:...

  • Page 517: Layout Of Warning Notices

    Guide to the Service Instructions Icon/symbol/ Meaning designation Fault rectification – Instructions to be carried out in accordance with fault messages. View additional steps. For example, “Contact a qualified electrician”. The requirements or tools outlined below must be ✓ met or available. Tests or inspections have been passed.
  • Page 518 Guide to the Service Instructions WARNING Indicates a dangerous situation in which an accident resulting in se‐ rious or fatal injuries may occur. ▶ After identifying the risk, instructions are set out which are inten‐ ded to avoid or remedy the risk. CAUTION There is a risk of injury to the entire body, however there is no risk of serious or fatal injuries.
  • Page 519 Safety regulations These safety regulations correspond to the “Maintenance and special work” section in the VDMA (German Engineering Federation) bro‐ chure “Safety manual for concrete delivery and placing machines”. ““Safety manual for concrete delivery and placing machines””. The safety regulations in the Operating Instructions must also be fol‐ lowed for all maintenance and special work.
  • Page 520 2 — 2 Service Instructions 210110691_2018-09-19_EN...

  • Page 521: Safety Regulations

    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 mainte‐ nance or as a result of use contrary to the designated use. This state‐...

  • Page 522: Welding

    Safety regulations Use specially designed or otherwise suitable climbing aids and work‐ ing platforms when carrying out assembly work above head height. Never use machine parts as climbing aids. Keep all handgrips, steps, railings, platforms and ladders free from dirt, snow and ice. Carefully secure individual parts and large assemblies to lifting equip‐...

  • Page 523: Working On The Placing Boom

    Safety regulations spected by qualified welding personnel. The operator must document the evidence of the formal qualifications of the welder and the quali‐ fied welding personnel. Always attach the earth cable of the welding unit directly to the com‐ ponent which is being welded. The welding current must not flow through hinges, cylinders, etc.

  • Page 524: Safetyrelevant Components

    Safety regulations The delivery line was installed without tension with the placing boom in the driving position and can only be replaced without difficulty in this condition. Stresses may be generated on folding if the delivery line is replaced when the placing boom is unfolded. Do not remove the entire delivery line but rather replace the delivery line boom arm by boom arm, for example.

  • Page 525: Electrical Power

    Safety regulations Keep all warning signs and information plates on the machine com‐ plete and in a perfectly legible condition. It is your responsibility as operator to ensure that any warning signs and information plates that have been damaged or rendered illegible are replaced without delay.

  • Page 526: Electrical Components

    Safety regulations If work is to be carried out on live parts, the presence of a second person is required who can switch off the power supply to the ma‐ chine in the event of an emergency. Secure the working area with a red-and-white safety chain and a warning plate.
  • Page 527 Safety regulations Always wear your personal protective equipment when carrying out work on the hydraulic system. Escaping fluid is toxic and can pene‐ trate the skin. Injection through the skin is a major medical emergency. In the event of injuries caused by pressurised fluid, inform the company medical officer and call a medical specialist immediately.

  • Page 528: Replacing Hydraulic Hoses

    Safety regulations The hydraulic system must be properly vented after all maintenance work. Otherwise there is a risk of injury caused by swinging and tele‐ scopic support legs extending rapidly, the placing boom lowering, etc. Open vent valves very carefully until hydraulic fluid starts to escape. You should on no account open vent valves further than necessary or go so far as to remove them.

  • Page 529: Functional Fluids

    Safety regulations ing up the engine in enclosed spaces, make sure that there is ade‐ quate ventilation and direct the exhaust gases away from the place of work. Wear personal protective clothing and equipment for all work in which exhaust gases or particles of building material can enter the body through the respiratory passages.

  • Page 530: Disposal Of The Machine

    Safety regulations Take care when handling hot functional fluids and consumables (risk of burning or scalding). Have used operating equipment and functional fluids such as filters, batteries, oil, brake fluid, etc. disposed of properly. Used cleaning rags should also be disposed of properly. 2.13 Disposal of the machine To dispose of the machine, you must proceed in accordance with all...
  • Page 531 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 3 — 1 210110691_2018-09-19_EN Service Instructions...
  • Page 532 3 — 2 Service Instructions 210110691_2018-09-19_EN...

  • Page 533: Safety Equipment

    Safety equipment Overview of the safety equipment Depending on the type of machine and its equipment, the following safety equipment may be fitted. Please see the machine card for de‐ tails about which safety equipment your machine has been fitted with. Carry out checks on the existing safety equipment according to the following descriptions within the specified intervals.

  • Page 534: Passive Safety Function

    Safety equipment 3.1.2 Passive safety function Intervals for inspec‐ Interval for function tion by a subject ex‐ check pert Separating protec‐ Annually each time a separat‐ tive devices ing protective device is removed Grille Annually Once a month 3.1.3 Organizational measures Intervals for inspec‐...
  • Page 535 Safety equipment Figure 1: SRP marking Item Designation Left Spare parts sheet Right Spare part packaging BP15_013_1412DE 2 Figure 2: Extract from an example spare parts sheet Item Designation Asterisk “*” – item cannot be ordered Exclamation mark “!” - Safety-related part (SRP) SRP service life in years 10 = 10 years 3 —...

  • Page 536: Safety Components

    Safety equipment Item Designation Hourglass – SRP service life Example spare parts sheet “EB00-5-xxxxx-xxxx” (3) for every safety-related part Putzmeister specifies a service life (SRP). The SRPs must be replaced once this service life has elapsed. 3.1.5 Safety components WARNING Risk of death due to malfunction ▶...

  • Page 537: Emergency Stop

    Safety equipment EMERGENCY STOP Safety function: Emergency shutdown function DIN EN ISO 13849-1:2016-06 Category 1 PL c Inspection Interval Intervals for inspection by annually subject expert Interval for function Before the machine is used each time checks 3.2.1 Description of the functions As soon as an EMERGENCY STOP is pressed, all dangerous BUTTON...

  • Page 538: Description Of The Functions

    Safety equipment 3.2.2 Function check It is only possible to intervene quickly in the event of danger if all the EMERGENCY STOP are working properly. BUTTONS 1. Switch on the core pump and agitator. 2. Operate a boom function. 3. Press one of the EMERGENCY STOP BUTTONS ⇒...
  • Page 539 Safety equipment The agitator safety cutout is triggered if an evaluation device is de‐ fective. Therefore, always check that the agitator safety cutout is working properly before using the pump. The LEDs on the evaluation device indicate the following: ● The green LED flashes for 8 seconds during the initialisation process.
  • Page 540 Safety equipment Safety action: ● The accumulator dump valve is opened and the accumulator is emptied. ● The agitator stops. ● The transfer tube stops. Technical action: ● The delivery pistons stop. 3.3.2 Function check Figure 4: Agitator safety cutout function check 1.
  • Page 541 Safety equipment 3.3.3 Acknowledging the agitator safety cutout WARNING Risk of injury The agitator can start up unexpectedly. 1. Do not tamper with the agitator safety cutout. 2. The machine must only be operated if the agitator safety cutout is intact. The agitator is secured against unexpected restarts.
  • Page 542 Safety equipment Figure 5: Control panel by the steps Item Designation Button “Acknowledge agitator safety cutout” 1. Press “Acknowledge agitator safety cutout”. When restarting, proceed as follows: 2. Switch off the core pump. 3. Switch on the core pump. Support monitoring safety system Safety function: Safety-related stop function, initiated by a protective device DIN EN ISO 13849-1:2016-06 Category 3 PL d...

  • Page 543: Description Of The Functions

    Safety equipment Inspection Interval Intervals for inspection by annually subject expert Interval for function Before the machine is used each time checks 3.4.1 Description of the functions Support monitoring is a safety system for flexible support for concrete pumps. The safety system monitors the following: ●...
  • Page 544 Depending on the machine model, the countdown is displayed either on the central module control cabinet or on the remote control. Have the fault rectified by a Putzmeister service technician immedi‐ ately. Once support monitoring is working correctly, the time is reset.
  • Page 545 Safety equipment Figure 6: Setup of the central control cabinet Item Designation Control panel on the central control cabinet Diagnostics socket Locally latched toggle switch with the following switch positions: “Local control” “0” “Remote control” “Process monitoring mode On − Off” keyswitch (Assembly not present) 3 —...

  • Page 546: Function Check

    Safety equipment 3.4.1.4 Red flashing light Figure 7: Example illustration of the red flashing light The red flashing light is fitted on both sides behind the driver’s cab. It is a warning which lights up once “Process monitoring mode 1” or “Process monitoring mode 2”...

  • Page 547: Support Control Block

    The support feet are depicted in blue (intermediate position) or green (fully lowered). If support monitoring is not functional: 3. Contact the Putzmeister After Sales department. Support control block Safety function: Enabling function DIN EN ISO 13849-1:2016-06 Category 1 PL d 3 —...

  • Page 548: Setting Up

    Safety equipment Inspection Interval Intervals for inspection by annually subject expert Interval for function Before the machine is used each time checks 3.5.1 Setting up on the left-hand side of the truck is illustra‐ SUPPORT CONTROL BLOCK ted below. The on the righthand side of the SUPPORT CONTROL BLOCK truck is a mirror image of this one.
  • Page 549 Safety equipment Item Designation Swing the rear support leg in and out EMERGENCY STOP button 3.5.1.1 Spirit level WARNING Risk of death caused by the machine toppling over 1. Support the machine at a maximum gradient of 3° to ensure that it remains stable.

  • Page 550: Method Of Operation

    Safety equipment 3.5.2 Method of operation 3.5.2.1 Two-hand control device is designed as a twohand control device, SUPPORT CONTROL BLOCK i.e. to execute a function, you must operate the PRESELECT LEVER the corresponding simultaneously. FUNCTION LEVER 3.5.2.2 Spring-loaded The hydraulic support valves are spring-loaded, i.e. the valves are au‐ tomatically reset to the zero position when you release the LEVERS 3.5.2.3...
  • Page 551 Safety equipment Prerequisites: ✓ Machine in driving position ✓ Parking brake applied ✓ Engine running ✓ Power takeoff switched on ✓ Support leg unlocked ✓ Remote control support function switched on WARNING Risk of death due to the support legs being incorrectly extended 1.
  • Page 552 Safety equipment WARNING Risk of injury in the swing-out and extension zone of the support legs There is a risk of injury as a result of crushing, impact, entangle‐ ment and shearing of various body parts caused by swinging and extending the support legs.

  • Page 553: Boom Support Cradle With Warning Signal

    Safety equipment Once a lever has been released, the valve must reset to the zero position of its own accord. 1. Extend or swing all support legs approximately halfway out, one after the other. ⇒ The relevant support leg stops moving as soon as you release one of the LEVERS 2.

  • Page 554: Description Of The Functions

    Safety equipment 3.6.1 Description of the functions The “Boom cradle with warning signal” boom cradle monitor checks whether the placing boom is correctly placed on the boom cradle. Once you lift the placing boom from the boom cradle while driving, an acoustic warning signal sounds in the driver’s cab, signifying that driv‐...

  • Page 555: Joysticks For Remote Control/Boom Control Block

    Safety equipment Only operate the machine if the boom cradle monitor is functioning. 1. Raise the placing boom slightly from the boom cradle. ⇒ The boom cradle switch is deactivated. 2. Switch off the power take-off. ⇒ The machine is in “driving” mode. ⇒...
  • Page 556 Safety equipment Figure 11: Remote control joysticks Item Designation Lefthand joystick Righthand joystick The boom control block is designed as an enabling function. The sig‐ nal from the remote control actuates “Boom function on” and the re‐ quired boom movement simultaneously. The valves are spring-loa‐ ded, i .e.
  • Page 557 Safety equipment Figure 12: Buttons on the boom control block Item Designation Arm 5 up Arm 5 down Arm 4 up Arm 4 down Arm 3 up Arm 3 down Arm 2 up Arm 2 down Arm 1 up Arm 1 down Slew the placing boom to the right Slew the placing boom to the left 3 —...

  • Page 558: Boom Control Block Function Check

    Safety equipment Item Designation Boom function on Support function on 3.7.1 Boom control block function check You can only operate the machine safely if the remote control and boom control block are fully functional. Prerequisites: ✓ Parking brake applied ✓ Power takeoff switched on ✓...

  • Page 559: Separating Protective Devices

    Safety equipment 4. Have a second person carry out a support function at the support control block. ⇒ You will be able to feel that the operating mode selector valve responds by attempting to electrically switch to the “Support function on” switch position. However, as you are manually forcing the switch into the “Boom function on”...
  • Page 560 Safety equipment Figure 13: Separating protective devices Item Designation Cardan shaft cover Snaplock on the support leg Four-point bearing/slewing ring cover Diagonal box/support leg covers Side underride protection Retaining rope on the end hose Securing cotter pins on delivery line couplings Water box cover Boom cradle cover (optional) Cover over the switch cylinders...

  • Page 561: Grille

    Safety equipment Grille Repair action Interval Replacement As soon as a bar reaches a re‐ sidual material thickness of 50% of its height or width at any point. 3.9.1 Description of the functions WARNING Risk of injury The hopper contains moving components. 1.

  • Page 562: Function Check

    6. Replace the grille if there are any visible breaks or cracks. If you have replaced the grille: 7. Have the agitator safety cutout readjusted by qualified personnel authorised by Putzmeister. 3.10 Plates Intervals for inspection by a sub‐...

  • Page 563: Description Of The Functions

    Safety equipment 3.10.1 Description of the functions Plates on the machine warn operators of dangers that cannot be pre‐ vented by means of the design. You will find the locations of the plates on the machine circuit dia‐ grams, which indicate which plate should be affixed where. 3.10.2 Function check 1.
  • Page 564 3 — 34 Service Instructions 210110691_2018-09-19_EN...
  • Page 565 Special modes of operation WARNING Risk of death during special operation 1. Only ever use special operating modes if you have received training on these by the manufacturer of the machine. 2. Only ever use special operating modes if you are authorised to do so by the operating company of the machine.
  • Page 566 4 — 2 Service Instructions 210110691_2018-09-19_EN...

  • Page 567: Special Modes Of Operation

    Special modes of operation Emergency operation of the boom function You can operate the placing boom manually at the boom control block in the event of a remote control malfunction. WARNING Risk of death If the machine is set up with limited support, you will be able to slew the placing boom out of the permissible working area using emer‐...
  • Page 568 Special modes of operation WARNING Risk of death during special operation 1. Only ever use special operating modes if you have received training on these by the manufacturer of the machine. 2. Only ever use special operating modes if you are authorised to do so by the operating company of the machine.

  • Page 569: Emergency Operation Of The Pump Function

    Special modes of operation Emergency operation of the pump function The hydraulic control valves are built into the pump control system. If the control system fails, you can operate the machine using the hy‐ draulic control valves. Figure 15: Setting up the pump control system Item Designation Accumulator...

  • Page 570: Emergency Operation Of The Transfer Tube

    Special modes of operation 4.2.2 Emergency operation of the transfer tube If the control system fails, you can switch over the transfer tube using the button. 4.2.3 Emergency operation of the delivery cylinder If the control system fails, you can operate the delivery cylinders us‐ ing the lever.

  • Page 571: Emergency Operation Of The Agitator

    Special modes of operation Figure 16: Emergency operation of the agitator and water pump Item Designation Agitator/water pumps shutoff valve Agitator changeover valve Water pump emergency operation Direction of agitator rotation emergency operation Agitator emergency operation 4.3.1 Emergency operation of the agitator (5) on the “Agi‐...

  • Page 572: Emergency Operation Of The High-Pressure Water Pump

    Special modes of operation 4.3.3 Emergency operation of the high-pressure water pump Prerequisites: Familiarise yourself with the structure of the high-pressure water pump in the Operating Instructions in the chapter “General technical description”. (3) on the 1. Press and hold the WATER PUMP EMERGENCY OPERATION “Agitator/water pump shut-off valve”.
  • Page 573 40 operating hours. The countdown is displayed on the remote control. ▶ Have the defect rectified by a Putzmeister service technician im‐ mediately. ⇒ Once support monitoring is working correctly, the time is reset.

  • Page 574: Ergonic 2.0 Central Module Control Cabinet

    Special modes of operation 4.4.1 ergonic 2.0 central module control cabinet Figure 17: Ergonic 2 central control cabinet Item Designation Keyswitch: Process monitoring mode on - off 4 — 10 Service Instructions 210110691_2018-09-19_EN...

  • Page 575: Ergonic 2.0 Remote Control

    Depending on the machine model, the countdown is displayed either on the central module control cabinet or on the remote control. 2. Get auxiliary personnel to observe with you. 3. Have the fault rectified by a Putzmeister service technician imme‐ diately. 4 — 11 210110691_2018-09-19_EN...

  • Page 576: Recovering The Machine After Faults Occur

    Special modes of operation Recovering the machine after faults occur WARNING Risk of death during special operation 1. Only ever use special operating modes if you have received training on these by the manufacturer of the machine. 2. Only ever use special operating modes if you are authorised to do so by the operating company of the machine.
  • Page 577 Special modes of operation 4.5.1.1 Emergency operation of the pump function The pump control system is equipped with hydraulic control valves which can be operated by hand. They are only for emergency manual operation of the machine when the control system fails. Figure 19: Covered pump control system Item Designation...
  • Page 578 Special modes of operation Figure 20: Setting up the pump control system Item Designation Accumulator Agitator and water pump control block Emergency operation of the transfer tube Emergency operation of the delivery cylinder Transfer tube damping cock Accumulator dump valve Pressure gauge (4) to the 3.
  • Page 579 Special modes of operation 4.5.1.2 Emergency operation of the boom function WARNING Risk of death If the machine is set up with limited support, you will be able to slew the placing boom out of the permissible working area using emer‐ gency operation of the boom function.
  • Page 580 Special modes of operation WARNING Risk of death during special operation 1. Only ever use special operating modes if you have received training on these by the manufacturer of the machine. 2. Only ever use special operating modes if you are authorised to do so by the operating company of the machine.
  • Page 581 Special modes of operation WARNING Risk of death It is not possible to observe the danger zone of the support while you are operating the boom control block. 1. Instruct another person to operate the boom control block so that you can operate the support control block and observe the danger zone of the support.

  • Page 582: Recovery With An External Hydraulic Power Pack

    Special modes of operation Item Designation Swing the rear support leg in and out EMERGENCY STOP button 2. Operate the “Support function on” on the support control LEVER block 3. Retract each of the support feet and support legs, one after the other.
  • Page 583 Special modes of operation NOTICE Machine damage The hydraulic system of the machine may become overloaded in the event of emergency supply. 1. Do not exceed the maximum emergency hydraulic supply rate of 60 l/min. 2. Do not exceed the maximum hydraulic fluid pressure for the emergency hydraulic supply of 350 bar.
  • Page 584 ● Fold the placing boom. ● Retract the support legs. We recommend the following emergency hydraulic unit, which comes as standard with the necessary accessories and is suitable for sup‐ plying Putzmeister concrete pumps in an emergency: Dynajet ® Plus ▶...
  • Page 585 Special modes of operation 4.5.2.1 Connecting an external hydraulic power pack Figure 22: Connecting an external hydraulic power pack Item Designation Boom control block Shut-off valve Vacuum return flow filter External hydraulic power pack Connector for intake line (yellow marking) Connection for pressure line (red marking) 1.
  • Page 586 Special modes of operation 4. Plug the end of the pressure line into the filler pipe of the hydraul‐ ic fluid reservoir and bleed the hydraulic pack by pumping a few litres of hydraulic fluid back into the hydraulic fluid reservoir under low pressure.
  • Page 587 Special modes of operation Emptying the delivery line Figure 23: Placing boom in rising position 1. Open the hinged elbow at the back of the hopper, so that the con‐ crete can flow out of the delivery line. 2. Press and hold the “Boom function on” button. 3.
  • Page 588 4 — 24 Service Instructions 210110691_2018-09-19_EN...
  • Page 589 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 are the maintenance work instructions for this machine. The table of contents contains an activity overview.
  • Page 590 5 — 2 Service Instructions 210110691_2018-09-19_EN...

  • Page 591: Maintenance

    Damage caused by inadequate maintenance 1. Have the first After Sales service after 100 operating hours car‐ ried out by a Putzmeister After Sales service engineer. The ma‐ chine operator responsible for the machine should be present during this service.
  • Page 592 Maintenance Assembly Action Interval daily 500 h annually other Replace the hydraulic fluid (fol‐ ✓ ✓ lowing fluid analysis) Replace hydraulic hoses 6 years (in‐ cluding a stor‐ age period of 2 years) Hydraulic fluid Check the contamination indica‐ ✓ filter Replacing the ventilation filter ✓...
  • Page 593 Maintenance Assembly Action Interval daily 500 h annually other Transfer tube Check wear ✓ Check and adjust the seal gap ✓ Check the tightening torque of ✓ the bolts (Lubricating Lubrication the transfer tube P. 5 — 67) Delivery line Safety lock of the couplings ✓...

  • Page 594: Residual Risks During Maintenance, Inspection And Repair Work

    Maintenance Assembly Action Interval daily 500 h annually other Cardan shafts Checking 250 hrs (in extreme Lubricate the cross pin bearings 50 hrs operating con‐ (if lubrication nipples are pres‐ ditions) ent) Truck engine In accordance with the truck manufacturer's maintenance information Truck trans‐...

  • Page 595: Auxiliary Devices

    Maintenance 5.2.3 Auxiliary devices Workshop equipment suitable for the work is absolutely necessary for carrying out maintenance, inspection and repair work. If you do not have access to qualified personnel, suitable workshop equipment, etc., you should commission the manufacturer's After Sales Department to assist with maintenance of your machine or component.
  • Page 596 Maintenance WARNING Risk of injury During work which cannot be carried out at ground level, there is a risk that you may fall from a large height. 1. Use suitable platforms or work stands. 2. Ensure that you are secure by using safety harnesses, railings or walkway barriers.
  • Page 597 Maintenance WARNING Risk of injury Damage to pipes and threaded unions may lead to high pressure in‐ jection of pressurized hydraulic fluid and to injury as a result of be‐ ing struck by detached hydraulic hoses. 1. Regularly inspect all lines and threaded unions for leaks and external damage before all pumping operations.

  • Page 598: General Tightening Torques

    Maintenance General tightening torques Tightening torques depend on the following values: ● bolt grade ● thread friction ● bolt head bearing area The values given in the following tables are for guidance. These val‐ ues should only be used if no other values are specified in the rele‐ vant chapters of the Operating Instructions or in spare parts sheets.

  • Page 599: Reassembly Of Walformplus Threaded Unions

    Maintenance Threaded unions Model [Nm] RAD = pipe external diameter = tightening torque Figure 25: Tightening the flared screwed joints 1. Using a spanner, tighten the union nut without excessive force. For flanged screw joints and profiled ring joints: 2. Use another spanner to hold the threaded connection in place while doing so.
  • Page 600 Maintenance 5.3.3.1 Tightening torques Figure 26: WALFORMplus threaded union setup Item Designation Threaded connection Union nut Pipe Seal The tightening torques are guide values, and only apply to opti‐ mum conditions. The torques may deviate substantially because of tolerance influences, pipes fitted under tension and incorrect lubri‐ cation.
  • Page 601 Maintenance WALFORMplus threaded union tightening torques Model [Nm] RAD = pipe external diameter = tightening torque WALFORMplus threaded union tightening torques Model [Nm] RAD = pipe external diameter = tightening torque 5.3.3.2 Fitting WALFORMplus threaded unions For the reassembly of the WALFORMplus threaded union, proceed as follows: 1.

  • Page 602: Folding Boom Cradle

    Maintenance 2. Clean the thread. ▶ Replace the parts that have a damaged thread. 3. Each time you undo a connection, check the seal for damage, ▶ and replace it if necessary. 4. For threaded unions made of rustproof steel, grease the thread and the reshaped area of the pipes with an adequate amount of EATONABF grease.

  • Page 603: Functional Fluids

    Maintenance Figure 27: Folding boom cradle Item Designation Left truck-side securing bolts Right truck-side securing bolts Folding axis Support edges Prerequisites: The placing boom must be raised. Fold the folding boom cradle as follows: (1) and on the 1. Loosen the securing bolts on the left truck side (2) .

  • Page 604: Hydraulic Fluids

    Never use hydraulic fluids or lubricants with additives such as molybdenum. 5.5.1 Hydraulic fluids See alsohttps://www.putzmeister.com/documents/58405/5728115/ CT_4748-2_DE_Hydraulikfluide.pdf The hydraulic system is filled with one of the following hydraulic fluids: ● Mineral hydraulic fluid (HLP) ● Synthetic ester-based biodegradable hydraulic fluid (HEES) ●...

  • Page 605: Level Of Contaminant

    Maintenance HEES synthetic esters and HFC aqueous solutions from different manufacturers must not be mixed together without prior approval from the manufacturers concerned. Use only a hydraulic fluid com‐ plying with the classification and requirement standards specified in the lubricant recommendation for topping up or a full hydraulic fluid change.

  • Page 606: Lubricant Analysis

    Lubricant recommendation You will find suitable lubricants and hydraulic fluids in the tables be‐ low. Putzmeister accepts no liability for the quality of the lubricants and hydraulic fluids listed or for changes in quality made by the lubri‐ cant manufacturer without changing the grade designation.
  • Page 607 Putzmeister accepts no liability for damages caused by mixing hy‐ draulic 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 608: Greases

    Maintenance 5.6.1 Transmission fluid Rotor gearbox Boom slewing Mixer drum gearbox Transfer gear‐ gear transmission Requirements see spare parts standard 51517-3:2018-09 51517-3:2018-09 51517-3:2018-09 sheet Characteristics synthetic mineral mineral Viscosity grade, CLP 220 CLP 220 CLP 220 NLGI Class Material no. 295246.006 000101.006 000101.006...
  • Page 609 Maintenance 5.6.3 Hydraulic fluids See alsohttps://www.putzmeister.com/documents/58405/5728115/ CT_4748-2_DE_Hydraulikfluide.pdf Mineral oil Synthetic ester Aqueous solution HEES 46 HFC 46 Classification DIN 51502:1990-08 DIN 51502:1990-08 DIN 51502:1990-08 DIN ISO DIN ISO DIN ISO 6743-99:2012-12 6743-99:2012-12 6743-99:2012-12 Requirement DIN 51524-2:2017-06 VDMA 24568 VDMA 24317/VDMA...

  • Page 610: Maintenance Work

    Maintenance Mineral oil Synthetic ester Aqueous solution HEES 46 HFC 46 Initial filling HLP 32 ● Material number: ● Material number: 484527 239879.002 ● Material number: ● Manufacturer: BE‐ ● Manufacturer: 490984 CHEM HYDRO‐ FUCHS HYDRO‐ HLP 46 STAR HEES 46 EEL THERM 46 M ●...
  • Page 611 Maintenance There are specific risks of accidents associated with maintenance, inspection and repair work. For this reason, read the chapter “Safety regulations” and the description of the residual risks in “Maintenance, inspection and repair work” at the start of this chap‐ ter.

  • Page 612: Lubricating The Boom Pedestal

    Maintenance (Checking hydraulic hose 2. Check all hydraulic hose lines for leaks. lines for leaks P. 5 — 46) (Checking the 3. Check all hydraulic unions for tightness and leaks. threaded unions P. 5 — 48) 5.7.2 Lubricating the boom pedestal The following maintenance work information describes lubrication of all lubrication points on the boom pedestal, if you have no centralised lubrication system.
  • Page 613 Maintenance 5.7.2.1 Lubrication points Figure 28: Lubrication diagram for boom pedestal Item Designation Snaplock Slewing cylinder Boom cradle switch ▶ Apply grease to the lubrication points until you can see it emerg‐ ing. 5.7.2.2 Lubrication points on telescopic support legs WARNING Risk of death caused by the machine toppling over Due to poorly lubricated telescopic support leg boxes, the telescopic...
  • Page 614 Maintenance The number of telescopic support leg boxes depends on the ma‐ chine model. Figure 29: Overview of lubrication points 5.7.2.3 Support foot (example illustration) WARNING Risk of death A high level of wear on the surface of the support foot inner tube can cause the support to fail.

  • Page 615: Lubricating The Placing Boom

    Maintenance Figure 30: Example illustration of a support foot 1. Clean the surface of the support foot inner tube weekly to remove dirt. 2. Lubricate the surface of the support foot inner tube with clean grease. 5.7.3 Lubricating the placing boom The following maintenance work information describes lubrication of all lubrication points on the placing boom.

  • Page 616: Maintaining The Cardan Shaft

    Maintenance Figure 31: Placing boom lubrication diagram Figure 32: Lubrication points for the delivery line coupling on the boom tip ▶ Apply grease until you can see it emerging. 5.7.4 Maintaining the cardan shaft The following maintenance work information describes inspecting, cleaning and lubricating of the cardan shaft.
  • Page 617 Maintenance There are specific risks of accidents associated with maintenance, inspection and repair work. For this reason, read the chapter “Safety regulations” and the description of the residual risks in “Maintenance, inspection and repair work” at the start of this chap‐ ter.
  • Page 618 Maintenance 5.7.4.1 Inspecting the cardan shaft Figure 33: Cardan shaft setup Item Designation Linear compensation Cardan shaft without lubrication nipple (maintenance-free) Joint Flange Cardan shaft with lubrication nipples Lubrication nipples (optional) Cross pin bearings Repair or replacement of the cardan shaft must only be carried out by an authorized specialist workshop.
  • Page 619 Maintenance (3) and linear compensation (1) , check 2. By raising the hinges whether there is any noticeable play. If there is noticeable play, arrange a repair. (3) for firm seating. 3. Check the bolts on the flange 4. Inspect the adjacent components for damage. (7) , check to see whether grease has 5.
  • Page 620 Maintenance The cross pin bearings of the cardan shaft must also be lubricated after cleaning or being stationary for more than six months. Lubricate the cross pin bearings of the cardan shaft directly at the lubrication nipples and not at the cross pin bearings. Figure 34: Overview of lubricating the cardan shaft Item Designation...

  • Page 621: Repairing The Centralised Lubrication System

    Maintenance If it is not possible for grease to visibly emerge from all four seals (3) , the cardan shaft must be repaired. on the cross pin bearings 5.7.5 Repairing the centralised lubrication system You must repair the centralised lubrication system if the lubricating pressure does not correspond to the working pressure range of the centralised lubrication system.
  • Page 622 Maintenance Prerequisites: ✓ You have initiated a lubrication procedure. Working pressure range of the centralised lubrication system Designation Value Minimum working pressure 20 bar Maximum working pressure 80 bar 1. Read off the lubricating pressure on the pressure gauge for lubri‐ cating pressure.

  • Page 623: Cleaning The High-Pressure Water Pump

    Maintenance ⇒ The lubricating pressure corresponds to the working pressure range of the centralised lubrication system. ⇒ The centralised lubrication system is operating without faults. Is lubricant not emerging from the lubrication points? The blockage in the lubrication line has not cleared. 1.
  • Page 624 Maintenance WARNING Risk of injury from severe pulsing caused by air in the plant 1. Check all quickrelease unions and quick-release couplers regu‐ larly for tightness and leaks. 2. Inspect the high-pressure hoses for damage and wear. 3. Regularly carry out a thorough inspection of the water system. WARNING Risk of injury 1.
  • Page 625 Maintenance 5. Top up with fluid if necessary. 0.3 l of fluid with an oil viscosity conforming to SAE 30 is required to fill the fluid reservoir completely. 6. Carry out the first fluid change after approximately 50 operating hours and then after every 500 operating hours. 5.7.6.1 Cleaning the screen 1.

  • Page 626: Hydraulic System

    Maintenance (2) . 5. Refit the screen (3) of the water filter back on. 6. Screw the lid 5.7.7 Hydraulic system 5.7.7.1 Drain off the condensation The following maintenance work information describes the draining of condensation from the hydraulic fluid reservoir. The control deadlines can be found in the overview at the start of this chapter.
  • Page 627 Maintenance See also the following sections: ● No further repair work is necessary. The following special tools are required: ● No special tools are necessary. Draining the hydraulic fluid reservoir Figure 37: Safety drain valve and blanking plug 1. Place a suitable container underneath to catch the condensation. 2.
  • Page 628 Result Corrective measure Green check mark None Yellow question mark Query the recommended measure with the Putzmeister After Sales de‐ partment. Red exclamation mark Have the hydraulic fluid completely changed by the Putzmeister Service department. Changing the hydraulic fluid in the hydraulic fluid reservoir...
  • Page 629 Maintenance NOTICE Machine damage The hydraulic fluid change described does not replace the complete hydraulic fluid change by the Putzmeister Service department. ▶ We recommend having the hydraulic fluid completely changed by the Putzmeister Service department. NOTICE Damage to the machine due to hydraulic systems that are not clean.
  • Page 630 Maintenance Prerequisites: ✓ You have carried out a lubricant analysis. ✓ The Putzmeister Service department has confirmed that changing the hydraulic fluid in the hydraulic fluid reservoir will be sufficient for the measured degree of contamination. ✓ The machine is in driving position.
  • Page 631 Maintenance Figure 39: Draining the hydraulic fluid 10. Remove the oil drain plug from the hydraulic fluid reservoir. 11. Drain off the hydraulic fluid. If there is a cleaning port on the side of the hydraulic fluid reser‐ voir: 12. Open the wash-out port. 13.
  • Page 632 Maintenance Figure 40: Filling the hydraulic fluid reservoir 1. Use only the hydraulic fluids specified in the lubricant recommen‐ dation. 2. Fill the hydraulic fluid reservoir with new hydraulic fluid via the screen in the filler pipe up to the “Maximum” marking. 3.
  • Page 633 Work on the hydraulic system must only be carried out by qualified personnel authorized by Putzmeister. Notify the Putzmeister After Sales department or the dealer or agency that you work with im‐ mediately if you find anything wrong.
  • Page 634 Maintenance NOTICE Environmental pollution Lubricants and functional fluids are damaging to the environment. 1. Carefully collect all functional fluids and operating equipment (e.g. used oil, including biologically degradable oil), filters and auxiliary materials. 2. Dispose of these materials separately from other waste. 3.
  • Page 635 Maintenance Figure 41: Checking hydraulic hose lines Dark and moist patches on the fitting are external signs of incipient damage. 3. Check the hydraulic hose lines for kinks, cracks or porous surfa‐ ces. 4. Ensure that the hydraulic hose lines are properly routed. Replacing hydraulic hose lines WARNING Risk of injury...
  • Page 636 Maintenance Hydraulic hose lines should not be more than six years old, includ‐ ing a storage time of two years. Please note the date of manufac‐ ture on the hydraulic hose lines. The following factors in particular accelerate wear on hydraulic hose lines: ●...
  • Page 637 Maintenance 5.7.7.5 Replacing the ventilation filter The following maintenance work information describes replacement of the ventilation filter element. NOTICE Environmental pollution Lubricants and functional fluids are damaging to the environment. 1. Carefully collect all functional fluids and operating equipment (e.g. used oil, including biologically degradable oil), filters and auxiliary materials.
  • Page 638 Maintenance Ventilation filter Filter element Maintenance indica‐ for ... Water tank Fuel tank Hydraulic fluid reser‐ voir Figure 43: Ventilation filter setup Item Designation Filter element 3-stage maintenance indicator Rotary knob, resets the maintenance indicator Screw cap with maintenance indicator Hydraulic fluid reservoir filter housing Fuel/water tank filter housing Screw cap without maintenance indicator...
  • Page 639 Maintenance NOTICE Damage caused by clogged filter element The filtering process can cause contamination particles to accumu‐ late in the filter housing. If these contamination particles are not re‐ moved when the filter is changed, the new filter element will quickly become clogged again.
  • Page 640 Maintenance NOTICE Material damage Commercially available filter elements do not meet Putzmeister's re‐ quirements. Cleaned filter elements have a lower flow rate than new filter ele‐ ments. 1. Only use original Putzmeister filter elements. 2. Always replace filter elements rather than cleaning them.
  • Page 641 Maintenance Where possible, fill the hydraulic system using a charging set. Do not leave the hydraulic fluid reservoir lid open for longer than necessary. Transport hydraulic fluid drums to the tapping point on drum trol‐ leys or suitable carts. ▶ Replace the filter element together with the vacuum return flow fil‐...
  • Page 642 4. Where possible, fill the hydraulic system using a charging set. NOTICE Material damage Commercially available filter elements do not meet Putzmeister's re‐ quirements. Cleaned filter elements have a lower flow rate than new filter ele‐ ments. 1. Only use original Putzmeister filter elements.
  • Page 643 Maintenance The following tasks must be carried out before changing the filter: 1. Switch off the hydraulic pumps. 2. Switch off the engine. 3. Dump the fluid pressure completely. 4. Switch off the remote control. 5. Secure the machine to prevent unauthorized start-up – remove the key from any that are present and interrupt the KEYSWITCHES...
  • Page 644 Maintenance Item Designation Filter element Magnetic rod 1. Place a container under the filter casing to allow you to catch the escaping hydraulic fluid. 2. Loosen the hexagon nuts up to the screw ends. 3. Pull out the filter insert up to the stop without turning it. ⇒...
  • Page 645 Maintenance Figure 45: Filter chambers of the vacuum return flow filter Item Designation Filling opening – rear filter chamber Filling opening – forward filter chamber Drain valve – forward filter chamber Drain valve – rear filter chamber 1. Have a container with a capacity of at least 10 l to hand. ⇒...
  • Page 646 Maintenance Replacing the filter element Figure 46: Structure of the vacuum return flow filter Item Designation Bolt Cover 1. Remove the bolts from the cover. 2. Unscrew the cover. 5 — 58 Service Instructions 210110691_2018-09-19_EN...
  • Page 647 Maintenance Figure 47: Structure of the vacuum return flow filter Item Designation Filter element Cover 3. Pull the filter element out, by turning it slightly anticlockwise. 4. Examine all components for mechanical damage, paying particu‐ lar attention to the sealing surfaces, thread and Orings. 5.
  • Page 648 Maintenance Replacing the suction filter element Figure 48: Filter setup Item Designation Hexagon nut (not present) Filter element Magnetic rod 1. Use a clean cloth to wipe the magnetic rod in the longitudinal di‐ rection. 2. Examine all components for mechanical damage, paying particu‐ lar attention to the sealing surfaces, thread and Orings.
  • Page 649 Maintenance As soon as hydraulic fluid emerges from the vent on the upper side of the vacuum filter: 11. Close the upper plug. Correction dimension The filter element must be the right length so that the filter housing can be opened to the rear. Use the length (correction dimension) given on the spare parts sheet.
  • Page 650 Maintenance Venting the vacuum return flow filter Figure 50: Filter chambers of the vacuum return flow filter Item Designation Filling opening – rear filter chamber Filling opening – forward filter chamber Drain valve – forward filter chamber Drain valve – rear filter chamber Prerequisites: ✓...
  • Page 651 Maintenance 5.7.8 Core pump 5.7.8.1 Inspecting the accumulator The following maintenance work information describes inspection of the pretensioning pressure. In Germany, the maintenance intervals are prescribed by the Industrial Health and Safety Ordinance [Be‐ triebssicherheitsverordnung (BetrSichV)]. Please note any applicable regulations in your country of use. WARNING Risk of injury Risk of burning and impact from explosions due to incorrectly filling...
  • Page 652 Maintenance Pressure Entry in the measurement re‐ cord Accumulator charge pressure BP18 (see glossary) Precharge pressure (see glos‐ BP19 sary) Figure 51: Setup on the accumulator Item Designation Accumulator Emergency operation of the transfer tube Emergency operation of the delivery cylinder Transfer tube damping cock 5 —...
  • Page 653 Maintenance Item Designation Pressure gauge Accumulator dump valve 1. Start the machine up. 2. Load the accumulator with hydraulic fluid until the pressure gauge displays the maximum accumulator charge pressure. 3. Switch off the engine. ⇒ The accumulator pump stops. ⇒...
  • Page 654 Maintenance In Germany, the inspection periods and the persons authorised to top up the accumulator depend on the category assigned according to the Industrial Health and Safety Ordinance [Betriebssicherheitsver‐ ordnung (BetrSichV)] and on the maximum permissible pressure: ● Hydraulic fluids and nitrogen belong to the fluids in Group 2 in ac‐ cordance with Directive 2014/68/EU.
  • Page 655 Maintenance 5.7.8.2 Lubricating the transfer tube The following maintenance work information describes lubrication of all lubrication points on the transfer tube in cases where you have no centralised lubrication system or the centralised lubrication system fails. There are specific risks of accidents associated with maintenance, inspection and repair work.
  • Page 656 The following special tools are required: ● No special tools are necessary. Damage to the delivery pistons must be rectified without delay. Putzmeister accepts no warranty claims for damage to the ma‐ chine resulting from failure to properly observe the maintenance regulations.
  • Page 657 Maintenance Shutting down the machine WARNING Risk of death 1. Pressure in the hydraulic system may cause sudden machine movements. 2. Dump the accumulator pressure completely. 3. Before commencing work on the plant, check the pressure gauge to ensure that the hydraulic fluid pressure in the plant has been completely dumped.
  • Page 658 Maintenance Closing the stroke correction lines Each drive cylinder stroke correction line has a ball valve (KEP) that is fitted open (markings parallel to the line) ex works and is locked against turning. Figure 53: Stroke correction line open Prerequisites: ✓...
  • Page 659 Maintenance Figure 54: As-fitted position of the guide washer Item Designation As-fitted position secured against rotation Rotate position You can carry out the following steps at the same time for both ball valves. 1. Remove the bolt on the handle. 2.
  • Page 660 Maintenance Figure 55: Turning the handle 7. Close the if both drive cylinders are no longer moving. BALL VALVE Once you have closed the ball valve, it may be that a drive cylinder moves again briefly until both drive cylinders are finally at the me‐ chanical end position.
  • Page 661 Maintenance Figure 56: Piston setup Item Designation Piston rod flange Fastening bolts Retaining rings Delivery piston Spacer flange 1. Shut the machine down. 2. Drain off the water from the water box. 3. Remove the cover of the water box. 4.
  • Page 662 Maintenance NOTICE Material damage The chrome layer of the delivery cylinder may be damaged. ▶ Do not use any hard objects or caustic cleaning agents to clean the delivery cylinder. 12. Thoroughly clean the delivery piston edge at the end of the water box.
  • Page 663 Maintenance 20. Put on the protective caps. 21. Start the machine up. 22. Retract the drive piston. ⇒ The spacer flange fits between the delivery piston and the drive piston. 23. Shut the machine down. 24. Insert the spacer flange. 25.
  • Page 664 Maintenance Figure 58: Turning and securing the ball valve 4. Rotate the guide washer by 90° and fit it so that it is blocked. 5. Fit the handle. 6. Securely screw in the handle. 7. Replace the second delivery piston in the same way. 8.
  • Page 665 The S transfer tube is subject to constant wear. Measuring the wall thickness is particularly important before starting on major con‐ tracts. You will obtain reliable results for your measurements if you carry out the test with the measuring device recommended by Putzmeister. 5 — 77 210110691_2018-09-19_EN Service Instructions...
  • Page 666 3. Replace pipes and elbows as soon as the wall thickness has fall‐ en below the guide value. Putzmeister accepts no liability if the wall thickness is less than the minimum wall thickness. 5 — 78...
  • Page 667 Maintenance As a rule, it is possible to continue pumping with an operating pressure lower than that shown in the graph. Due to dynamic loading during pumping, the delivery line is subjec‐ ted to different loads. There is no general method for calculating the minimum wall thickness for this load, which depends on indi‐...
  • Page 668 Maintenance The following special tools are required: ● No special tools are necessary. The following tightening torques are required: ● The tightening torques can be found in the corresponding spare parts list. Use only suitable lifting equipment for lifting components. Prerequisites: The machine must be shut down.
  • Page 669 Maintenance Removing the transfer tube bearing The S transfer tube is seated in the rear hopper wall with the transfer tube bearing. Figure 60: Opening on the S transfer tube with transfer tube bearing Item Designation Fastening bolts Transfer tube bearing Wedge Spring pin Retaining bolt for hinged elbow...
  • Page 670 Maintenance CAUTION Risk of injury The hinged elbow may fold out automatically if you remove the chock from the retaining bolt. 1. Hold the hinged elbow firmly in place when removing the chock. 2. Secure the unfolded hinged elbow with a cable or similar during maintenance work.
  • Page 671 Maintenance The mounting position for the gasket set in the transfer tube bear‐ ing can be found in the corresponding spare parts sheet. 1. Grease the new gasket set. 2. Bend the grooved ring to make installation easier. 3. Insert the gasket set as shown on the spare parts sheet. 4.
  • Page 672 Maintenance Note the location of the lubrication openings when fitting the trans‐ fer tube bearing (2). (2) onto the S transfer tube outlet. 1. Fit the transfer tube bearing 2. Bolt down the transfer tube bearing. Closing the hinged elbow Figure 63: Hinged elbow lock Item Designation...
  • Page 673 Maintenance Item Designation Wedge Tie rod for retaining bolt Spring pin (2) must be screwed onto the tie rod (6) (Letter‐ The retaining bolt (1) facing upwards). Only in this way can the ing “0” or milling (5) be used for locking the hinged elbow. chock (2) .
  • Page 674 Maintenance The following special tools are required: ● No special tools are necessary. The following tightening torques are required: ● The tightening torques can be found in the corresponding spare parts list. Use only suitable lifting equipment for lifting components. 9 10 Figure 64: Overview of the switching shaft bearing Item...
  • Page 675 Maintenance Item Designation Switching shaft Hexagon nut Switching shaft bearing Pulling bore for switching shaft bearing (two diagonally opposite each other) Fastening bolt for switching shaft bearing (covered) Shutting down the machine WARNING Risk of death 1. Pressure in the hydraulic system may cause sudden machine movements.
  • Page 676 Maintenance Removing the switching shaft bearing NOTICE Environmental pollution Lubricants and functional fluids are damaging to the environment. 1. Carefully collect all functional fluids and operating equipment (e.g. used oil, including biologically degradable oil), filters and auxiliary materials. 2. Dispose of these materials separately from other waste. 3.
  • Page 677 Maintenance 5. Place a container under the bulkhead union as well. 6. Unscrew the hydraulic hose that leads to the plunger cylinder from the bulkhead union. 7. Catch the hydraulic fluid flowing out of the hydraulic line and hy‐ draulic hose. 8.
  • Page 678 Maintenance 12. Remove the plunger cylinder with the hydraulic hose. 13. If required, remove the hydraulic hose from the plunger cylinder . 14. Remove the second plunger cylinder in the same way. Figure 67: Overview of slotted slewing locking mechanism Item Designation Clamping bolts...
  • Page 679 Maintenance Figure 68: Overview of the switching shaft bearing Item Designation Fastening bolt Pulling bores (two, diagonally opposite each other) Switching shaft bearing 18. Suspend the transfer tube from suitable lifting equipment. 19. Unscrew the fastening bolt on the switching shaft bearing. 20.
  • Page 680 Maintenance Replacing the switching shaft bearing gasket set Figure 69: Removing the retaining ring 1. Remove the retaining ring. Figure 70: Removing the old grooved ring 2. Remove the old gasket set. 3. Cut the rings open if necessary. 5 — 92 Service Instructions 210110691_2018-09-19_EN...
  • Page 681 Maintenance Figure 71: Inserting the new grooved ring For the mounting position of the grooved ring in the flanged bear‐ ing, please refer to the accompanying spare parts sheet. 4. Clean the switching shaft bearing. 5. Grease the new gasket set. 6.
  • Page 682 Maintenance Replacing the switching shaft bearing wear sleeve and collared wash‐ Figure 72: Overview of switching shaft bearing wear sleeve Item Designation Switching shaft bearing wear sleeve Switching shaft bearing Collared washer Bore 1. Bend the tab of the collared washer downwards. 2.
  • Page 683 Maintenance 2. When fitting the switching shaft bearing, note the position of the lubrication openings. 3. Grease the inside of the wear sleeve and the outside of the switching shaft bearing with “anti-seize agent AS 450 assembly paste” or similar assembly grease. 4.
  • Page 684 Maintenance Item Designation Flattened tooth Notch 6. Grease the teeth of the switch lever and the switching shaft with “anti-seize agent AS 450 assembly paste” or similar assembly grease. 7. Bolt down the switching shaft bearing. 8. Place the O-ring in the wear sleeve. The flattened tooth of the switching shaft must align with the centre of the switch lever for the transfer tube to be in the correct position.
  • Page 685 Maintenance Figure 74: Retaining plate assembly 15. Fit the retaining plate . 16. Fit the fastening bolts on the retaining plate. Vent the hydraulic system after complete assembly if you have re‐ moved the hydraulic hoses from the plunger cylinders. Slowly start the pump and switch the transfer tube over slowly sev‐...
  • Page 686 Maintenance We recommend that the slewing locking mechanism also be re‐ placed when the S transfer tube is replaced. Practical experience has shown that the toothing on the switching shaft and that on the slewing locking mechanism wear together as a result of the forces generated during switchover.
  • Page 687 Maintenance Use only suitable lifting equipment for lifting components. Prerequisites: The machine must be shut down. The steps required to achieve this are detailed below. Use the remote control here. Shutting down the machine WARNING Risk of death 1. Pressure in the hydraulic system may cause sudden machine movements.
  • Page 688 Maintenance S transfer tube variants Figure 75: S transfer tubes Item Designation S transfer tube with bolted switching shaft S transfer tube with welded switching shaft Whichever variant of S transfer tube is fitted, the recommended pro‐ cedure for dismantling is as described below. Removing the S transfer tube Prerequisites: Replace the S transfer tube if the wall thickness has fallen below the...
  • Page 689 Maintenance Figure 76: Removing the mixer shaft 5. Remove the mixer shaft. Figure 77: Lifting out the S transfer tube 6. Unbolt the scratch bar from the bottom of the S transfer tube. 7. Push the S transfer tube forwards until the transfer tube outlet is uncovered.
  • Page 690 Maintenance If just the wear sleeve is heavily worn, you can also replace just (Replacing the S the wear sleeve and then refit the S transfer tube. transfer tube wear sleeve P. 5 — 113) 9. Fit the new S transfer tube. To do this, proceed in the reverse or‐ der to removal.
  • Page 691 Maintenance There are specific risks of accidents associated with maintenance, inspection and repair work. For this reason, read the chapter “Safety regulations” and the description of the residual risks in “Maintenance, inspection and repair work” at the start of this chap‐ ter.
  • Page 692 Maintenance Shutting down the machine WARNING Risk of death 1. Pressure in the hydraulic system may cause sudden machine movements. 2. Dump the accumulator pressure completely. 3. Before commencing work on the plant, check the pressure gauge to ensure that the hydraulic fluid pressure in the plant has been completely dumped.
  • Page 693 Maintenance Removing the spectacle wear plate Figure 78: Spectacle wear plate setup Item Designation Plunger cylinder Switch lever Switching shaft Hexagon nut Fastening bolts for spectacle wear plate 1. Shut the machine down. 2. Loosen the hexagon nut on the switching shaft. (Replacing the switching shaft 3.
  • Page 694 Maintenance Figure 79: Pushing the S transfer tube to one side If there is not enough space available for assembly, you can pull the pressure connection towards the back. 4. Push the S transfer tube away from the spectacle wear plate. 5.
  • Page 695 Maintenance Replacing the intermediate rings Figure 80: Intermediate ring setup Item Designation Transition liner Intermediate ring Screw plug Lubrication nipple Grease gun 5 — 107 210110691_2018-09-19_EN Service Instructions...
  • Page 696 Maintenance 1. Using a plastic-faced hammer, strike the old intermediate ring a few times from the front. ⇒ Any concrete and grout residue is loosened. 2. Replace the screw plug on the underside of the transition liner with the lubrication nipple from the accessories. 3.
  • Page 697 Maintenance Figure 82: Overview of O-rings Item Designation Intermediate ring O-rings O-rings for sealing the delivery cylinder Transition liner 8. Stretch the O-rings over the mounting surface of the new inter‐ mediate ring. 9. Grease the mounting surface of the new intermediate ring. 10.
  • Page 698 Maintenance Figure 83: Inserting the O-ring 13. Insert an O-ring in the groove on the front of each intermediate ring. 5 — 110 Service Instructions 210110691_2018-09-19_EN...
  • Page 699 Maintenance Fitting the spectacle wear plate Figure 84: Setup for using the spectacle wear plate Item Designation Fastening bolts on the left and right Spectacle wear plate Fastening bolts at the top and bottom Intermediate ring Oring Hopper wall Clearance 1.
  • Page 700 Maintenance If you have a ceramic spectacle wear plate, please contact our Af‐ ter Sales department to enquire about the tightening torques. 3. Using the fastening bolts at the top and bottom, screw on the spectacle wear plate to the appropriate tightening torque. Take care to ensure that the spectacle wear plate does not be‐...
  • Page 701 Maintenance NOTICE Damage to the spectacle wear plate If there are lubrication nipples in the pulling bores and these are al‐ so lubricated when lubricating the machine, the intermediate rings will be pushed out. This would cause the spectacle wear plate to become warped.
  • Page 702 Maintenance WARNING Risk of death The hydraulic system is pressurized. Sudden machine movements may occur during operation. 1. Shut the machine down. 2. Secure the machine against unauthorized or accidental starting There are specific risks of accidents associated with maintenance, inspection and repair work.
  • Page 703 Maintenance Shutting down the machine WARNING Risk of death 1. Pressure in the hydraulic system may cause sudden machine movements. 2. Dump the accumulator pressure completely. 3. Before commencing work on the plant, check the pressure gauge to ensure that the hydraulic fluid pressure in the plant has been completely dumped.
  • Page 704 Maintenance 1. Shut the machine down. (Replacing the transfer tube 2. Remove the transfer tube bearing. bearing P. 5 — 79) . 3. Loosen the hexagon nut on the switching shaft and the clamping (Replacing the switching bolts on the slewing locking mechanism. shaft bearing P.
  • Page 705 Maintenance If the S transfer tube has been fitted, proceed as follows: 1. Weld a metal pin onto the wear sleeve. (1) on the front between the 2. Carefully cut open the welding points (2) and wear sleeve (3) using an angle S transfer tube outlet grinder.
  • Page 706 Maintenance Fitting the wear sleeve Figure 87: Fitting the wear sleeve Item Designation Wear sleeve Transfer tube outlet (1) is chrome-plated, and therefore must not be The wear sleeve heated unevenly or to too high a temperature. (1) evenly to approx. 140 °C. 1.
  • Page 707 Maintenance 5.7.8.10 Replacing the thrust ring and wear ring The following maintenance work information describes replacement of the thrust ring and wear ring of the S transfer tube. The mainte‐ nance intervals can be found in the overview at the start of this chap‐ ter.
  • Page 708 Maintenance Prerequisites: The machine must be shut down. The steps required to achieve this are detailed below. Use the remote control here. Shutting down the machine WARNING Risk of death 1. Pressure in the hydraulic system may cause sudden machine movements.
  • Page 709 Maintenance (Re‐ 4. Inspect the spectacle wear plate and replace it if required. placing the spectacle wear plate P. 5 — 102) Figure 88: Thrust ring and wear ring Item Designation Thrust ring Wear ring (2) and the old thrust ring (1) . 5.
  • Page 710 Maintenance 5.7.8.11 Adjusting the S transfer tube The following maintenance work information describes setting of the S transfer tube. ● Pretensioning the S transfer tube. ● Adjust the switching overlap between the wear ring and spectacle wear plate on the S transfer tube. Replace the wear parts if one of the following faults occurs: ●...
  • Page 711 Maintenance Shutting down the machine WARNING Risk of death 1. Pressure in the hydraulic system may cause sudden machine movements. 2. Dump the accumulator pressure completely. 3. Before commencing work on the plant, check the pressure gauge to ensure that the hydraulic fluid pressure in the plant has been completely dumped.
  • Page 712 Maintenance Prestressing the S transfer tube Figure 89: Hopper area setup Item Designation Spectacle wear plate Wear ring S transfer tube Thrust ring Hexagon nut Retaining plate Slewing locking mechanism 1. Shut the machine down. (4) does not become damaged during Ensure that the thrust ring injection.
  • Page 713 Maintenance (3) and wear ring (2) , a gap (5) must Between the S transfer tube (3) switches over correctly. be retained so that the S transfer tube (2) is touching the 3. Check all sides to ensure that the wear ring (1) .
  • Page 714 Maintenance 6. Allow the transfer tube to switch over once. 7. Shut the machine down. Figure 91: Spectacle wear plate Item Designation Marking on the spectacle wear plate Figure 92: Swing angle variants Item Designation Swing angle too great Swing angle too small Optimum swing angle 8.
  • Page 715 Maintenance Figure 93: Plunger cylinder with packing washer Item Designation Plunger cylinder (switch cylinder) Ball cup Packing washer 9. Replace the packing washer behind the ball cup on the right-hand plunger cylinder with a thicker or thinner one as required in order to correct the left-hand switching overlap.
  • Page 716 Maintenance Spectacle wear plate with example markings Figure 94: Various packing washers Item Designation Packing washer too thin Packing washer too thick Optimum packing washer To reduce the swing angle of the transfer tube by 4 mm, the integra‐ ted packing washer must be replaced with one that is 2 mm thicker. To increase the swing angle of the transfer tube by 4 mm, the integra‐...
  • Page 717 Maintenance Figure 95: Plunger cylinder with locking plate Item Designation Plunger cylinder (switch cylinder) Locking plate 1. Disassemble the locking plate from the extended plunger cylin‐ der . Figure 96: Removing the plunger cylinders 2. Push the piston of the extended plunger cylinder back a little and remove the plunger cylinder with the hydraulic hoses.
  • Page 718 Maintenance Figure 97: Plunger cylinder ball cup Item Designation Ball cup Packing washer 3. Remove the ball cup. 4. Remove the packing washer. NOTICE Material damage ▶ Do not place any packing washers into the slewing locking mechanism, as doing so may cause the plunger cylinder to run onto the edge of the ball cup.
  • Page 719 Maintenance 11. Check and correct the switching overlap of the other wear plate side. 5.7.9 Delivery line 5.7.9.1 Measuring the wall thickness of the delivery line The following maintenance work information describes measuring the wall thickness of delivery lines. The maintenance intervals can be found in the overview at the start of this chapter.
  • Page 720 You will obtain reliable results for your measurements if you carry out the test with the measuring device recommended by Putzmeister. Only tap the delivery line with a piece of hardwood (hammer han‐ dle). Otherwise, dents may be created and these will lead to more rapid wear.
  • Page 721 Maintenance The wear on the outer radius of an elbow is greater than on the inter‐ nal radius or on straight pipes. 2. Measurements on the outer radii of elbows must therefore be car‐ ried out with particular care. 3. The minimum wall thickness for elbows is shown in the wall thick‐ ness graph below.
  • Page 722 Maintenance Measuring Figure 100: Minimum wall thickness as a function of operating pressure Item Designation High pressure Maximum delivery pressure 5 — 134 Service Instructions 210110691_2018-09-19_EN...
  • Page 723 4. Replace pipes and elbows as soon as the wall thickness has reached the value for the minimum wall thickness. Putzmeister accepts no liability if the wall thickness is less than the minimum wall thickness. As a rule, it is possible to continue pumping with an operating pressure lower than that shown in the graph.
  • Page 724 Maintenance WARNING Risk of death Concrete can escape from the delivery line if it is pressurized. The delivery line may be pressurized even when the concrete pump is switched off. 1. Do not open the delivery line if it is still pressurized. 2.
  • Page 725 Maintenance Observe all safety instructions in the machine-specific Operating Instructions and in the Safety manual. Inspecting two-layer delivery pipes and delivery line elbows Model Minimum (mm) DN 125 up to 85 bar Twin Pipe Twin Cast Delivery line 7.1 + 3.6 elbow 7.0 + 2.0 Delivery pipe...
  • Page 726 Maintenance 1.1 - 1.2 Elbows Measuring point P1/P2 mini‐ mum dimension (see table) 2.1 - 2.4 Delivery pipe Measuring point P1/P2 mini‐ mum dimension (see table) Table 3: Extract from Esser Service Manual - EM 070190, see Technical Appendix Proceed as follows to check the two-layer delivery pipes and elbows 125, max.
  • Page 727 Maintenance WARNING Risk of death The hydraulic system is pressurized. Sudden machine movements may occur during operation. 1. Shut the machine down. 2. Secure the machine against unauthorized or accidental starting WARNING Risk of injury Carrying out installation work on the delivery line can result in con‐ veyed material spraying out and parts falling.
  • Page 728 Maintenance There are specific risks of accidents associated with maintenance, inspection and repair work. For this reason, read the chapter “Safety regulations” and the description of the residual risks in “Maintenance, inspection and repair work” at the start of this chap‐ ter.
  • Page 729 Maintenance Figure 102: Placing boom rating plate Manufacturer data Item Designation Manufacturer's address Placing boom data Item Designation Model Placing boom no. Material no. (MN) Year of manufacture Max. horizontal reach Max. vertical reach Max. end hose Hydraulic pressure max. Max.
  • Page 730 Maintenance Item Designation Data for the delivery line on the placing boom Item Designation MN (material number) DN (nominal diameter) Model (maximum permitted outside diameter and wall thickness of the delivery line) Coupling type (AL = aluminium, ST = steel) L1 - L6: Arm assembly adapter pipe lengths End hose data Item...
  • Page 731 Maintenance Prerequisites: You have familiarised yourself with how to measure wall thicknesses in the following sections: (Measuring the wall thickness of the S transfer tube P. 5 — 76) ✓ ( Measuring the wall thickness of a two-layer pipe P. 5 — 135) ✓...
  • Page 732 Maintenance Figure 103: The adapter pipe length plate is located on the placing boom When ordering the distance tubes, always specify the following infor‐ mation: Designation Example Machine number 21/..the mounting position L3.1 Length in mm 1377 mm the nominal diameter ND.
  • Page 733 Maintenance ⇒ In the driving position, the arm assembly is not under tension if each arm is resting loosely on the boom cradle provided for this purpose. ⇒ When unfolded, the arm assembly is not under tension if each arm is supported. Keeping a distance 1.
  • Page 734 Maintenance Securing the coupling Couplings with a lever lock must be secured with a spring safety clip. Figure 104: Spring safety clip on couplings with a lever lock Couplings with a screw lock are screwed on using self-locking nuts. 1. Replace these nuts for each new assembly, and do not use them again.
  • Page 735 Maintenance Fitting an A seal Figure 105: Adjusting the clearance with a feeler gauge 1. Push the A seal over the fixed delivery line pipe. 2. Lay the pipe to be attached in the pipe bracket and push it up to the fixed pipe.
  • Page 736 Maintenance Figure 106: The spacing is set automatically by the seal ring 1. Push the C seal over the weld-on ring of the fixed delivery line pipe. 2. Lay the pipe to be attached in the pipe bracket and push it up to the fixed pipe.
  • Page 737 Maintenance Use multipurpose grease with a lithium soap base and K2K mark‐ ing. 1. Grease all couplings and seals well internally before assembly. 2. At the pivot points, fit the elbows in the mounting couplings. 3. Align the elbows so that the straight pipes can be connected stress-free.
  • Page 738 ▶ If you find a loose connecting bolt, have it replaced immediate‐ ly, and only by qualified personnel authorised by Putzmeister. There are specific risks of accidents associated with maintenance, inspection and repair work. For this reason, read the chapter “Safety regulations”...
  • Page 739 A dull sound means that the bolt is loose. A sharp sound means that the bolt is firmly screwed in place. 2. If you find a loose connecting bolt, have it replaced immediately, and only by qualified personnel authorised by Putzmeister. 5.7.10.2 Maintaining the slewing gear transmission The following maintenance work information describes the fluid level check and full fluid change on the slewing gear transmission.
  • Page 740 Maintenance There are specific risks of accidents associated with maintenance, inspection and repair work. For this reason, read the chapter “Safety regulations” and the description of the residual risks in “Maintenance, inspection and repair work” at the start of this chap‐ ter.
  • Page 741 Maintenance ⇒ The oil level must not be below the lower edge of the inspec‐ tion glass or 30 mm below the oil filler or below the “minimum” marking of the oil dipstick. Full fluid change ▶ Carry out the first fluid change after 500 operating hours. Fill the gearbox with oil 1.
  • Page 742 5 — 154 Service Instructions 210110691_2018-09-19_EN...
  • Page 743 Index Index In this chapter, you will find the most important keywords and the number(s) of the page(s) on which they appear. This index of key words is in alphabetical order.  P. 5 — 31 Cleaning the cardan shaft  P. 4 — 6  P.
  • Page 744 Index    P. 5 — 13 Emergency operation of the agitator and water pumps Fitting WALFORMplus threaded unions P. 4 — 6  P. 5 — 14 Folding boom cradle  P. 4 — 3, Emergency operation of the boom function  P. 1 — 3 Foreword 4 —...
  • Page 745 Index  P. 1 — 5  P. 2 — 10 Layout of warning notices Noise emissions  P. 5 — 17 Level of contaminant  P. 5 — 18 Lubricant analysis  P. 5 — 75 Opening the stroke correction lines  P. 5 — 18 Lubricant recommendation  P.
  • Page 746 Index    P. 5 — 79 Recovery with an external hydraulic power pack Replacing the transfer tube bearing P. 4 — 18   Replacing the transfer tube bearing gasket set  P. 3 — 16 P. 5 — 82 Red flashing light  P.
  • Page 747 Index  P. 3 — 20 Spring-loaded  P. 5 — 69, 5 — 80, 5 — 99, Starting up the machine 5 — 104, 5 — 115, 5 — 120, 5 — 123  P. 5 — 18 Storage of lubricants  P. 5 — 132 Straight pipes  P.
  • Page 748 C — 6 Service Instructions 210110691_2018-09-19_EN...

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