Page 1 Operating Instructions for the machine operator and maintenance personnel always keep by the machine Translation of the original instructions Compressed air conveyor EstrichBoy DC 450 Machine no. 3-0120 365500000_en...
Page 2 Digital spare parts lists Dear customer, You can find the appropriate spare parts list for your machine at: https://www.putzmeister.com/group/service-center/technical-documentation2 If you do not yet have access to our website, you can sign up at: https://www.putzmeister.com/ For quick access, a corresponding QR code can be found in the control box. The QR code takes you to the directory in which the spare parts lists are stored.
Page 3: 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 4 Table of contents . . . 2.6.2 Operation outside Germany .................... 2 — 11 Personnel selection and qualifications ................2 — 11 2.7.1 Training ........................... 2 — 12 2.7.2 Qualified personnel ......................2 — 12 2.7.3 Subject expert ......................... 2 — 12 Sources of danger ......................
Page 5 Table of contents . . . General technical description ..........3 — 1 Machine model ........................ 3 — 3 Overview ......................... 3 — 3 Motor compartment ......................3 — 4 Technical data ......................... 3 — 5 Electromagnetic compatibility (EMC) ................3 —...
Page 6 Table of contents . . . Preparing the transport ....................4 — 4 4.3.1 Transport position ......................4 — 4 4.3.2 Lighting equipment ......................4 — 5 Towing gear ........................4 — 7 4.4.1 Ball hitch/towing ring ....................... 4 — 7 4.4.2 Adjusting the towing gear ....................
Page 7 Table of contents . . . 5.4.4 Switching off the machine ....................5 — 13 Safety equipment function check ..................5 — 13 5.5.1 EMERGENCY STOP button ................... 5 — 15 5.5.2 Checking the protective grille cutout ................5 — 17 Operation ................
Page 8 Table of contents . . . 6.15 Cleaning .......................... 6 — 32 6.15.1 General ........................... 6 — 32 6.15.2 Cleaning the machine ..................... 6 — 33 6.15.3 Cleaning the delivery line ....................6 — 35 6.15.4 Cleaning with a highpressure cleaner ................6 —...
Page 9 Table of contents . . . 7.2.5 The starter cranks the engine when the “Engine selector switch” is actuated. The 7 — 14 engine does not start....................... 7.2.6 The engine starts, but immediately stops again when the “Engine selector switch” is 7 —...
Page 10 Table of contents . . . 8.4.14 Checking the safety valve ....................8 — 55 8.4.15 Changing the fuel filter ....................8 — 57 8.4.16 Drain the fuel filter (with water-separating filter) .............. 8 — 60 8.4.17 Centralised lubrication system – checking the fill level ........... 8 —...
Page 11 Guide to the Operating Instructions In this chapter you will find notes and information that will help you use these Operating Instructions. If you have any queries, please contact us in confidence at: Putzmeister Mörtelmaschinen GmbH Max-Eyth-Straße 10 72631 Aichtal, Germany Tel.: +49 (0)7127 599-0 Fax: +49 (0)7127 599-743 E-mail: info@estrichboy.de...
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Page 13: 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 applications as designated. The Operating Instructions contain important information on how to operate the machine safely, properly and economically. Observing these instructions helps to avoid danger, to reduce repair costs and downtimes and to increase the reliability and service life of the ma‐...
Page 14: Icons And Symbols
Guide to the Operating Instructions In the event of any amendment, the copy of the Operating Instruc‐ tions intended for the machine will be replaced in full. The reproduction, distribution and utilisation of this document as well as the communication of its contents to others without explicit authori‐ sation is prohibited.
Page 15: Layout Of Warning Notices
Guide to the Operating Instructions Icon/symbol/ Meaning designation Special tools are required. This icon is followed by a list of special tools that are required to carry out the task. (Normal tools, i.e. conventional tools or tools carried in the vehicle, are not listed spe‐ cially.) This icon is followed by an indication of required maintenance work.
Page 16 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 17: Safety Regulations
Safety regulations This chapter summarises the most important safety regulations. This chapter must be read and understood by all persons who come into contact with the machine. The various regulations also appear again at the appropriate points in the Operating Instructions. Special safety regulations may be necessary for some tasks.
Page 18 2 — 2...
Page 19: Definition Of Terms
Safety regulations Definition of terms The following sections explain the terms used in these operating in‐ structions and describe the requirements for specific groups of per‐ sonnel. 2.1.1 Compressed air conveyor Compressed air conveyors are machines designed to convey mix ma‐ terial through the delivery line to the site of concrete placement ac‐...
Page 20: Service Technician
Safety regulations 2.1.7 Service technician Personnel qualified or authorised by the manufacturer to perform maintenance tasks. 2.1.8 Maintenance Maintenance includes all measures required to inspect and repair a machine. 2.1.9 Workplace The workplace is the area in which people must remain in order to carry out the work.
Page 21: Onwards Sale
Safety regulations Observe the following basic principles: ● Safety equipment must not be removed, decommissioned or other‐ wise modified. ● Safety equipment removed for maintenance work must be fitted again as soon as work is complete. ● Following assembly, the safety equipment must be checked to en‐ sure it is fully functional.
Page 22: Improper Use
Safety regulations The machine only serves to mix, pump and spray screed, sand, grav‐ el and concrete with a particle distribution of up to 16 mm. It may only be used for delivery on construction sites. The maximum delivery pressure must not exceed the value specified on the rating plate. All protective covering elements of the machine must be fitted during operation.
Page 23: Removal Or Modification Of Safety Equipment
Safety regulations 2.4.2 Removal or modification of safety equipment Depending on the model, the machine is fitted with different safety equipment for protection against serious personal injury. Removing, modifying or decommissioning safety equipment is pro‐ hibited. If safety equipment has been modified, damaged, removed or is not fully functional, the machine must be shut down and secured immedi‐...
Page 24: Transport
Safety regulations 2.4.7 Transport The machine may only be transported as stated. During transport, lift‐ ing equipment, lifting tackle or other auxiliary devices that are unsuita‐ ble or not reliable and safe in operation must not be used. Loading the machine with unauthorised materials and accessories, as well as exceeding the maximum permissible gross weight of the machine, is prohibited.
Page 25: Changing The Works Settings
Safety regulations 2.4.10 Changing the works settings The works settings must not be changed. A few examples are listed below: ● Pressure and performance settings ● Software versions and software parameters 2.4.11 Structural changes Structural changes must not be implemented without permission from the manufacturer.
Page 26: Exclusion Of Liability
Safety regulations The safety and accident prevention regulations from the following in‐ stitutions must be observed: ● The legal authority of the country of use ● The Industrial Employers’ Liability Insurance Associations ● The responsible commercial liability insurance company The legal authority places liability for accidents caused by not observ‐ ing safety and accident prevention regulations or by lack of care with the operating personnel or (where they cannot be held responsible due to lack of training or basic knowledge) the supervisory personnel.
Page 27: Operation In Germany
Safety regulations The CE marking on the machine and compressor equipment as well as declarations of conformity certify that our products meet the re‐ quirements outlined in all the relevant Directives. The declarations of conformity are passed to the customer when the machine is deliv‐ ered.
Page 28: Training
Safety regulations ● Persons who can be expected to reliably execute the tasks with which they are charged ● Persons who have been explicitly tasked with the stated activities by the employer 2.7.1 Training The machine must only be operated, serviced or maintained by trained subject experts.
Page 29: Danger From Hot Machine Components
Safety regulations Make sure than no one can be endangered by the machine starting up before you switch on the machine. Do not loosen or tighten pressurised threaded unions. 2.8.2 Danger from hot machine components During and after work, there is a risk of burning from hot parts of the motor and the frame.
Page 30: Personal Protective Equipment
Safety regulations All equipment required for safety and accident prevention (warning signs and information plates, cover grilles, guards, etc.) must be in place. Such equipment must not be removed, modified or damaged. All warning and information plates on the machine must be complete and fully legible at all times.
Page 31 Safety regulations Symbol Meaning Hearing protectors Hearing protectors protect you against the noise generated in the vicinity of the machine when you are standing close to it. (DIN EN 352-1:2003; Hearing protectors - General requirements - Part 1: Earmuffs or DIN EN 352-3:2003;...
Page 32: Protective Equipment For Work With High-Pressure Water Jets
Safety regulations Symbol Meaning Safety harness When working at heights, use climbing aids and platforms that are intended for this pur‐ pose and comply with the safety regulations or wear a safety harness. Relevant national regulations must be observed. (DIN EN 361:2002; Personal protective equip‐ ment against falls from a height - Full body harnesses;...
Page 33 Safety regulations WARNING Risk of injury due to high-pressure water jet The machine operator must be informed that waterproof protective clothing only provides protection from spray water and splash parti‐ cles. In case of direct contact with the high-pressure water jet, sufficient protection against injuries caused by the high-pressure water jet is not guaranteed.
Page 34: Risk Of Injury, Residual Risks
Safety regulations 2.12 Risk of injury, residual risks The machine has been built in accordance with state of the art tech‐ nology and meets all the relevant safety requirements. Nevertheless, its use may constitute a residual risk to life and limb of the machine operator or of third parties, or cause damage to the machine and to other property.
Page 35: Risk Of Crushing And Impact
Safety regulations ● Risk of being struck, entangled, drawnin and caught by the ten‐ sioned scraper cable. ● Risk of crushing when opening and closing the drum lid. ● Pressure hazards. 2.13 Risk of crushing and impact 2.13.1 Operating modes There is a risk of crushing and impact at the machine during the fol‐...
Page 36: Discharge Stand
Safety regulations 2.13.4 Discharge stand WARNING Risk of impact due to swinging discharge stand, especially if there are blockages in the delivery line. 1. Make sure that no persons or objects are located in the danger zone of the discharge stand. 2.
Page 37: Blockages
Safety regulations Work on the electrical systems and equipment of the machine must only be carried out by a qualified electrician or by instructed persons under the supervision and guidance of a qualified electrician and in accordance with electrical engineering rules and regulations. 2.15 Blockages Blockages increase the risk of accidents.
Page 38: Hydraulic And Pneumatic System
Safety regulations If the blockage is not released, switch off the entire machine. Relieve pressure in the mixer drum and, above all, the delivery line and re‐ move the affected delivery line section and remove the blockage. WARNING Risk of injury due to pressurised mixer drum or delivery line 1.
Page 39: Conduct In An Emergency
Safety regulations Depressurise sections of the system and pressure lines (hydraulic and pneumatic system, delivery line) which you intend to open prior to commencing repair work in line with the assembly descriptions. Check the pressure gauge indicator to ensure that the affected sys‐ tem sections and pressure lines are depressurised.
Page 40: Storing The Machine
Safety regulations Accessories not included in the products supplied with the ma‐ chine are supplied by the manufacturer and can be purchased via the Parts Sales department. The supplied accessories are listed on the delivery note. The operating company is responsible for ensuring that the correct accessories are used.
Page 41: Unauthorised Start-Up Or Use Of The Machine
Safety regulations All soundproofing equipment must be fitted and in perfect condition. It must be fitted during operation. A high sound level can cause perma‐ nent hearing damage. 2.22 Unauthorised start-up or use of the machine 2.22.1 Operating modes There is a danger posed by unauthorised start up or use of the ma‐ chine during the following operating modes: ●...
Page 42: Safety-Related Parts (Srps)
Safety regulations 2.24 Safety-related parts (SRPs) WARNING Risk of death Incorrect assembly of safety-related parts can result in malfunc‐ tions. ▶ Safety-related parts (SRP) should only ever be repaired, main‐ tained or replaced by qualified personnel with the necessary au‐ thorization.
Page 43 Safety regulations BP15_013_1412DE 2 Figure 3: 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 Hourglass – SRP service life Example spare parts sheet “EB00-5-xxxxx-xxxx”...
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Page 45: General Technical Description
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) auxiliary equipment is also described. 3 — 1...
Page 46 3 — 2...
Page 47: Machine Model
General technical description Machine model Your machine is an EstrichBoy from Putzmeister Mörtelmaschinen GmbH. The following data can be found on the rating plate: ● Machine model ● Machine number You will make it much easier for us to respond to any questions or orders if you give us the details of the machine model and the ma‐...
Page 48: Motor Compartment
General technical description Item Designation Loading hopper device (B/BS) Lighting equipment Feed hopper Mixer drum with agitator Air valve fittings Operating panel Support wheel Motor compartment Figure 5: Motor compartment overview Item Designation Control console Control cabinet Drive motor Motor dry air filter 3 —...
Page 49: Technical Data
General technical description Item Designation Fuel tank Compressor air filter maintenance indicator Radiator assembly Compressor dry air filter Hydraulic fluid reservoir Hydraulic fluid filter Oil trap Compressor Battery Centralised lubrication system Technical data Dimensions EB DC 450 EB DC 450 B EB DC 450 BS Length with 4790 mm...
Page 50 General technical description Axle and EB DC 450 EB DC 450 B EB DC 450 BS wheels Technically 100 km/h permissible Observe the maximum speed limit in force in the maximum country of use. speed Towing ring In line with DIN 74054 Part 1 Tyres EB DC 450 EB DC 450 B...
Page 51 General technical description Performance EB DC 450 EB DC 450 B EB DC 450 BS data Max. particle size of con‐ 16 mm veyed material Sound power See plate on the machine. level Sound pres‐ > 85 dB(A) sure level Inclination an‐...
Page 52 General technical description Fill vol‐ EB DC 450 EB DC 450 B EB DC 450 BS umes Motor oil 9 litres with filter change Compres‐ 11 litres sor oil Transmis‐ 4.4 litres sion fluid Fuel Diesel fuel, approx. 70 litres Hydraulic fluid reser‐...
Page 53: Electromagnetic Compatibility (Emc)
General technical description Mixer drum Permissible load cycle number 50000 (Nper) Test pressure for recurrent hy‐ As specified in national regula‐ draulic strength test tions (for Germany, in line with Industrial Health and Safety Or‐ dinance (BetrSichV): 1.3 x PS) Regular inspections for promptly detecting incipient damage are particularly important because the mixer drum is dynamically stressed.
Page 54: Rating Plate
General technical description Rating plate The most important machine specifications are shown on the rating plate. Figure 6: Rating plate Item Designation Model (machine model) Year of manufacture Max. delivery pressure [bar] Max. hydraulic pressure [bar] Voltage [V] Frequency [Hz] Power [kW] Identification number for certification and monitoring office CE marking...
Page 55: Sound Power Level
General technical description Sound power level Next to the rating plate on the machine there is the plate shown in the picture below, which gives the machine's sound power level measure‐ ment. Figure 7: Plate – sound power level Item Designation Sound power level Value in decibels...
Page 56: Safety Equipment
General technical description ● BluePower ● Automatic mixer drum lid Depending on the mix material, we recommend using wear plates in the cylindrical area and on the base of the mixer drum to extend the service life of the mixer drum. For further options and accessories, please refer to the Catalogue (Art.
Page 57 General technical description NOTICE Machine damage caused by incorrect actuation of the EMERGEN‐ CY STOP button 1. Only press the EMERGENCY STOP button in the event of dan‐ ger. 2. Do not use the EMERGENCY STOP button to switch off the machine.
Page 58: Protective Grille With Safety Switch
General technical description 3.9.2 Protective grille with safety switch DANGER Risk of death due to removed protective grille Amputations resulting from the crushing, shearing, entanglement or drawing of limbs into the rotating mixing apparatus. 1. Make sure that the protective grille is fitted in every operating mode.
Page 59: Description Of The Functions
General technical description The rods of the protective grille are wear parts. As soon as the re‐ maining material on a protective grille rod decreases to 50% of the original height or width at any point, the protective grille must be re‐ placed.
Page 60: Control Cabinet
General technical description The mixing apparatus in the mixer drum on the machine consists of a mixer shaft with boltedon mixing paddles and is used to thoroughly mix the water, binder and aggregate. The mixing apparatus is driven by the engine via V-belts and a Car‐ dan shaft.
Page 61: Overview
General technical description 3.11.2 Overview Figure 10: Control cabinet (under the hood) Item Designation Control cabinet Toggle switch for radio remote control Switches the radio remote control for the scraper on/off. Electrical plug-in connection (cable harness) Master switch (double push-button) Switches the power supply on/off.
Page 62 General technical description Figure 11: Control console overview Item Designation Indicating instrument Displays and messages “Drive motor” selector switch Drive motor OFF – ON – START (engage – engage – tap) “Mixer” illuminated button Mixer ON/OFF “Pumping functions” selector switch MANUAL –...
Page 63 General technical description 3.12.1.1 Indicating instrument The indicating instrument is located on the operating panel Figure 12: Indicating instrument Item Designation LED lights 1 to 8 Display Eight LEDs are arranged on the indicating instrument. These serve to visualise the operating states. If a fault occurs or a warning is issued, the LEDs indicate the corresponding state for the benefit of the opera‐...
Page 64 General technical description Colour Symbol Function Description Yellow Option (Option) depend‐ ing on model: Message: - Hydraulic system Hydraulic sys‐ fill level too low. tem fill level Top up the fill lev‐ Yellow Message: Battery charge state too low. Battery Charge the battery charge state Display...
Page 65 General technical description Display Description Mixing time extension If required, information for the “Mixing time exten‐ sion” option is displayed in the main display area. When the mixing time potentiometer is actuated, the setting value is shown for approx. 10 seconds in the display area.
Page 66 General technical description Warning Description Engine oil pressure The engine oil pressure is checked approx. 5 sec‐ onds after start-up. If the oil pressure is not reached, the engine is switched off. The LED lights up in red. The display background turns red and the symbol is shown.
Page 67 General technical description Message Description Battery charge state The battery charge state is too low. The engine is not switched off and it may not be possible to re‐ start it. The LED lights up in yellow. The display background turns yellow and the symbol is shown.
Page 68 General technical description Display Description Safety circuit open The safety circuit was opened. This occurs when the EMERGENCY STOP button is actuated or the protective grille is opened. The engine is switched off and cannot be restarted. The display background turns red and the symbol is shown.
Page 69 General technical description Display Description Remixing time This symbol indicates the remixing time. When the potentiometer is actuated, the setting value is shown for approx. 10 seconds after the symbol. Once the mixing time extension has been started, the value of the remaining remixing time is dis‐ played Centralised lubrication system service function This symbol indicates that the centralised lubrica‐...
Page 70 General technical description Item Designation Status display Scraper activation button Transmitter (on the scraper blade) Battery in the transmitter EMERGENCY STOP button (on the transmitter) The scraper is operated via a radio remote control system. The trans‐ mitter attached to the scraper blade is impact and splash-resistant. The receiver is located under the hood near the control cabinet.
Page 71: Drive Motor
General technical description 3.13 Drive motor Figure 14: Drive motor overview Item Designation Drive motor Generator Oil filler Oil dipstick Fuel filter Oil filter Dry air filter Silencer The drive motor values can be found on the rating plate or in the “Technical data”...
Page 72: Compressed-Air System
General technical description 3.14 Compressed-air system The compressed-air system generates the compressed air required to transport the material from the mixer drum to the placement site. The compressor is driven by the drive motor. The compressor draws in fresh air via the dry air filter and compacts it to the required operat‐ ing overpressure.
Page 73: Hydraulic System
General technical description This automatic delivery stop offers machine operators the following advantages: ● The machine operator can leave the machine after initiating the delivery process, the cut-out occurs automatically. ● The delivery lines are guaranteed not to be blown empty, thus pre‐ venting the material from segregating.
Page 74: Loading Hopper Device
General technical description 3.17 Loading hopper device Figure 16: Filling the loading hopper The loading hopper device can be used to prepare a new mortar mix in the loading hopper during the delivery process. The loading hopper is raised hydraulically. The loading hopper is hinged on the machine's mixer drum and is raised when the machine is being transported by road.
Page 75: Scraper Equipment
General technical description 3.18 Scraper equipment Figure 17: Scraper Item Designation Scraper winch Scraper blade Loading hopper The scraper equipment can be used to fill the loading hopper quickly and efficiently. The scraper equipment can even be used to mound together sand piles which are scattered far apart from one another.
Page 76: Centralised Lubrication System
General technical description 3.19 Centralised lubrication system Figure 18: Centralised lubrication system Item Designation Lubricant reservoir Lubrication nipple Lubricant reservoir filling point The centralised lubrication system supplies the two mixer shaft bear‐ ings with lubricant. The lubricant reservoir is filled on the lubricant reservoir filling point or the lubrication nipple.
Page 77: Highpressure Cleaner
General technical description 3.20 Highpressure cleaner As an option, the machine can be equipped with a high-pressure cleaner. The highpressure cleaner is used to clean the outside of the machine with pressurised water. The high-pressure cleaner is powered by a hydraulic drive. NOTICE Machine damage due to the high-pressure cleaner running dry 1.
Page 78 General technical description Item Designation Trigger Securing lever The control range of the high-pressure cleaner is from 5 to 140 bar and depends on the number of motor revolutions. The pressure can be regulated by turning the handwheel. There is a trigger safety on the lever of the high-pressure gun to se‐ cure it against being activated accidentally.
Page 79 Transport, setting up and connection In this chapter you will find information concerning safe transport of the machine. In this chapter, you will furthermore find information on tasks necessary for the assembly and connection of the machine. Starting up the machine is described in the “Starting up” chapter. 4 —...
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Page 81: Transport, Setting Up And Connection
Transport, setting up and connection Transport and driving Putzmeister trailer machines may only use public roads with the rele‐ vant approval. If they are being towed in road traffic, they are subject to road traffic regulations. These will also specify the permissible driv‐ ing speed for the trailer machine in the country of use.
Page 82: Preparing The Transport
Transport, setting up and connection Preparing the transport Before the machine may be moved by a tractor unit in road traffic, the following aspects must be prepared: The tractor unit must be equipped with a trailer coupling complying with DIN specifications. 1.
Page 83: Lighting Equipment
Transport, setting up and connection 4.3.2 Lighting equipment The machine is fitted with lighting equipment. WARNING Risk of injury due to lighting equipment not being fully functional ▶ Always check the function of the lighting before the start of a journey.
Page 84 Transport, setting up and connection Figure 21: Lighting equipment driving position Item Designation Lighting equipment Lighting equipment bracket on the mixer drum Spring pin 1. Before the start of a journey, place the lighting equipment in the bracket at the rear of the mixer drum and secure it with the spring pins.
Page 85: Towing Gear
Transport, setting up and connection Towing gear The tractor unit must be equipped with a trailer coupling designed to withstand the relevant trailer and drawbar loads. Figure 23: Attaching the machine horizontally The machine must have maximum ground clearance while being tow‐ ed.
Page 86: Parking Brake
Transport, setting up and connection Figure 24: Towing gear Item Designation Towing gear Locking toggle Spring pin Handle 1. Pull out the spring pin on the locking toggle . 2. Release the locking toggle and turn it as far as the stop. ⇒...
Page 87: Brake Safety Cable
Transport, setting up and connection The axle and wheels are equipped with a pneumatic spring. The pneumatic spring assists the braking force. If the automatic reverse braking system is activated (machine rolling backwards), the pneu‐ matic spring automatically retightens the wheel brake. The machine must be secured with the parking brake when parked: WARNING Danger due to the machine rolling away...
Page 88: Ball Hitch
Transport, setting up and connection WARNING Danger due to accidental tensioning of the brake safety cable 1. In normal driving mode, there must not be any tension on the brake safety cable under any circumstances when the trailer is attached. The brake safety cable must not be completely taut even when travelling around a corner.
Page 89: Ball Hitch Engagement Indicator
Transport, setting up and connection Figure 26: Ball hitch Item Designation Ball hitch Engagement indicator Wear indicator Hitch handle 4.6.1 Ball hitch engagement indicator The green engagement indicator functions as a safety display on the front of the ball hitch. When the ball hitch is correctly engaged, the green engagement indicator is pushed out and becomes visible.
Page 90: Permissible Ball Hitch Slewing Circle
Transport, setting up and connection DANGER Risk of accident due to worn ball hitch or tractor unit ball If wear is present, the trailer is no longer safely hitched to the tractor unit. The ball hitch can become unhitched. 1. Make sure that the trailer is no longer moved. 2.
Page 91: Hitching The Ball Hitch
Transport, setting up and connection Hitching the ball hitch To hitch the trailer, proceed as follows. WARNING Risk of accident The trailer may only be moved if it is properly hitched. 1. Hitch the ball hitch properly. If the ball hitch is not properly hitched, the trailer may disconnect from the tractor unit.
Page 92 Transport, setting up and connection Figure 28: Hitching the ball hitch Item Designation Hitch handle Lock Engagement indicator Pulling the hitch handle upwards – open Engaging the hitch handle on the ball of the tractor unit Pushing the hitch handle all the way downwards (locked) – engagement indicator is visible WARNING Risk of crushing...
Page 93: Disconnecting The Ball Hitch
Transport, setting up and connection In case of higher drawbar loads, a support wheel can be used to facilitate raising/lowering, depending on the model. 4. In addition, push the hitch handle all the way down by hand for good measure. The hitch mechanism is properly locked if the (C) .
Page 94: Selecting A Setup Site
Transport, setting up and connection WARNING Risk of crushing Even low pressure on the spherical cap can activate the springloa‐ ded closing mechanism and cause an injury. ▶ Do not reach into the open ball hitch. 3. Open the ball hitch by actuating the lock and pulling the hitch handle upwards.
Page 95: Setting Up The Machine
Transport, setting up and connection WARNING Risk of injury due to falling items People may be seriously injured or killed by falling items. 1. Set up the machine outside the danger zone of elevated work‐ places. 2. Protect workplaces at the machine with suitable protective roofs.
Page 96: Setting Up The Machine Without Support Feet
Transport, setting up and connection 4.10.1 Setting up the machine without support feet Figure 29: Setting up the machine Item Designation Support foot holder Timber block Chock Crank handle (support wheel) Parking brake 1. Secure the machine against rolling away by placing chocks under the wheels.
Page 97: Setting Up The Machine With Support Feet
Transport, setting up and connection 4.10.2 Setting up the machine with support feet Figure 30: Setting up the machine Item Designation Support foot Connecting bolt Spring pin Chock Crank handle (support wheel) Parking brake 1. Secure the machine against rolling away by placing chocks under the wheels.
Page 98: The Delivery Line
Transport, setting up and connection Before transporting the machine, the support feet must be placed in transport position again. 4.11 The delivery line Use only original Putzmeister delivery lines that can withstand the specified operating and bursting pressures. Only Putzmeister couplings and connections guarantee compli‐ ance with the values specified in the German Accident Prevention Regulation.
Page 99: Installing And Connecting The Delivery Line
Transport, setting up and connection WARNING Risk of injury due to contaminated couplings. Contaminated couplings are not properly sealed and allow water to leak out under pressure. This causes blockages. ▶ Only couple line couplings which have been cleaned and have fully functional gaskets.
Page 100 Transport, setting up and connection Figure 31: Installing the delivery line Item Designation Support trestle Delivery line Discharge stand 1. Connect the delivery line to the pressure connection. 2. Install the delivery line so that it passes over a support trestle or the drawbar immediately downstream of the machine.
Page 101 Transport, setting up and connection Figure 32: Connecting the discharge stand Item Designation Discharge stand Delivery line 5. If necessary, clean the connections of the delivery line and the discharge stand. 6. Connect the delivery line to the discharge stand. 4 —...
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Page 103 Starting up This chapter contains information on starting up the machine. It de‐ scribes the work steps required for the initial commissioning of the machine and how to prepare the machine before use after longer breaks. There is also a description on how to check the condition of your machine and how to carry out a test run with function checks.
Page 104 5 — 2...
Page 105: Starting Up
Starting up Inspection prior to commissioning in line with the Industrial Health and Safety Ordinance Since 1st March 2005, Putzmeister Mörtelmaschinen GmbH has pro‐ vided a special service for compressed air conveyors intended for the German market, where the inspection is already successfully comple‐ ted under reference conditions prior to commissioning according to Art.
Page 106: Checking The Functional Fluids
Starting up 1. Check that all safety equipment is fitted and fully functional. 2. Check the protective grille for wear. Replace the protective grille if the residual material thickness of the grille rods falls below 50%. 3. Check the most important wear parts, such as the mixing appara‐ tus, etc.
Page 107 Starting up WARNING Risk of injury due to skin contact with functional fluids Hydraulic fluid and other functional fluids can be injurious to health in case of skin contact. ▶ Always wear your personal protective equipment when handling toxic, caustic or other functional fluids that can be injurious to health and observe the manufacturer’s information.
Page 108: Checking The Dry Air Filter
Starting up 5.2.3 Checking the dry air filter Check the maintenance indicator on the dry air filter. The filter ele‐ ment must be cleaned or replaced if the red area is visible in the win‐ dow of the maintenance indicator. 1.
Page 109: Checking The Mixer Shaft Bearings
Starting up 5.2.7 Checking the mixer shaft bearings Mixer shaft bearings must be replaced: ● If the sealing washers are torn (visible in the mixer drum). ● If the mixer shaft pins are worn (radial play). ● If cement grout escapes at the gearbox-side bearing. ●...
Page 110: Filling The Machine With Fuel
Starting up Filling the machine with fuel WARNING Risk of injury due to fuel igniting Smoking is absolutely prohibited when fuelling. 1. Fill the machine with fuel only when the engine is switched off. 2. Keep a fire extinguisher readily available while fuelling. 3.
Page 111: Switching On The Machine
Starting up 5.4.1 Switching on the machine The machine power supply is switched on at the main switch. The main switch for the machine is located on the control cabinet, which is under the hood in the motor compartment. Figure 33: Control cabinet Item Designation Control cabinet...
Page 112: Start Engine
Starting up 5.4.2 Start engine The compressor and hydraulic system are switched on and off with the engine. All functions are only available when the engine is switch‐ ed on. Figure 34: Control console Item Designation Indicating instrument Displays and messages Engine selector switch Engine OFF –...
Page 113 Starting up Turning the Engine selector switch to the “START” position while the engine is running does not trigger a start sequence. Start termination: The start signal is reset if the engine does not start within 15 seconds. A new start attempt is not possible until a waiting period of 10 seconds has passed.
Page 114: Switching Off The Engine
Starting up 5.4.3 Switching off the engine Figure 35: Control console – shut down the motor Item Designation Indicating instrument Displays and messages Engine selector switch Engine OFF – ON – START (engage – engage – tap) 1. Stop all active functions (mixer, delivery, etc.). 2.
Page 115: Switching Off The Machine
Starting up 5.4.4 Switching off the machine Before the machine power supply can be switched off, all active func‐ tions must be stopped and the drive motor switched off. Figure 36: Control cabinet Item Designation Control cabinet Master switch (double push-button) In case of longer downtimes, the machine should be cleaned be‐...
Page 116 Starting up WARNING Risk of injury due to defective safety equipment 1. If a safety device does not respond during the check, the ma‐ chine must not be started up. 2. Eliminate the fault. Check: 1. The function of the EMERGENCY STOP button, 2.
Page 117: Emergency Stop Button
Starting up 5.5.1 EMERGENCY STOP button 5.5.1.1 Checking the EMERGENCY STOP button EMERGENCY STOP buttons are located on the operating panel and, as an option, on the radio remote control for the scraper. Figure 37: Control console Item Designation Indicating instrument Displays and messages Engine selector switch Engine OFF –...
Page 118 Starting up ⇒ The engine is switched off immediately. ⇒ All running functions are switched off immediately. ⇒ The “Safety circuit open” display appears on the indicating in‐ strument. ⇒ The background of the display turns red. 5.5.1.2 Restarting after EMERGENCY STOP After resetting the EMERGENCY STOP, all faults must be rectified and all EMERGENCY STOP buttons must be unlocked and acknowl‐...
Page 119: Checking The Protective Grille Cutout
Starting up After the EMERGENCY STOP button has been unlocked, the ma‐ chine does not start up automatically. 2. Turn the Pumping functions selector switch to position “0”. 3. Acknowledge the EMERGENCY STOP by pressing the push-but‐ ton. ⇒ The “Version” display appears on the indicating instrument for 7 seconds.
Page 120 Starting up Figure 39: Protective grille Item Designation Mixer drum Protective grille Protective grille lever To trigger the protective grille cutout: (Start engine P. 5 — 10) . 1. Start the engine 2. Switch the mixer on by pressing the “Mixer illuminated button”. 3.
Page 121 Starting up Before the engine can be restarted, the protective grille must be closed and the protective grille lever locked. The safety circuit must be closed again and the and protective grille cut-out acknowl‐ edged. To switch the machine back on: 4.
Page 122 5 — 20...
Page 123: Operation
Operation This chapter contains information on operating the machine. It ex‐ plains the work steps required for setting, operation and cleaning. 6 — 1...
Page 124 6 — 2...
Page 125: Requirements
Operation Requirements You must have completed the operations for setting up and starting up the machine before you begin operating the machine. Before you fill the machine with material and start pumping it through the delivery line, you must make sure that: ●...
Page 126: Switching The Mixing Apparatus On/Off
Operation 5. Unlock the EMERGENCY STOP button, acknowledge the fault and switch the machine on again (see the “Starting up” chapter, “EMERGENCY STOP button” section). Switching the mixing apparatus on/off Figure 40: Control console Item Designation “Drive motor” selector switch Drive motor OFF –...
Page 127: Switching Off The Mixing Apparatus
Operation 6.3.2 Switching off the mixing apparatus ▶ Switch the mixer off by pressing the “Mixer” illuminated button. ⇒ The mixing apparatus is switched off. ⇒ A started delivery is stopped immediately. ⇒ The lamp in the “Mixer” illuminated button goes out. Operating the loader Depending on the version, your machine may be fitted with a loading hopper device.
Page 128 Operation To prevent damage to the lighting equipment when swivelling down the loading hopper device, it must be placed in the intended bracket. (Setting up the machine 1. Position the machine correctly P. 4 — 17) . 2. Place the lighting equipment in the intended bracket to work with the machine.
Page 129: Switching On The Radio Remote Control
Operation Switching on the radio remote control Figure 42: Radio remote control for scraper Item Designation Control cabinet Radio remote control toggle switch Receiver (under the hood) Battery in charging station Status display Scraper activation button Transmitter (on the scraper blade) Battery in the transmitter EMERGENCY STOP button (on the transmitter) Make sure that there is a battery in the transmitter.
Page 130: Operating The Scraper
Operation The Si 2 LED for the status display lights up when the scraper is actuated. Operating the scraper Depending on the model, your machine may be fitted with a scraper. The scraper is operated via a radio remote control (see the “General technical description”...
Page 131: Prelubricating The Delivery Line
Operation NOTICE Risk of damage to the winching mechanism ▶ Do not use the scraper to push material located next to the loading hopper. This would put a high stress on the winching mechanism and damage it. 1. Hang the scraper blade on the traction cable. (Switching on the radio remote 2.
Page 132 Operation Figure 44: Connecting the discharge stand Item Designation Discharge stand Delivery line (Switching on the ma‐ 1. Switch the machine on at the main switch chine P. 5 — 9) . 2. Connect the discharge stand to the end of the delivery line. Figure 45: Prelubricating the delivery line Item Designation...
Page 133: Fill Mixer Drum
Operation 7. Open the mixer drum lid. 8. Fill the mixer drum with water. The water volume should correspond to approximately 10% of the total volume of the delivery line. Only then is it possible to wet the entire inner wall of the delivery line. One metre of the delivery line holds approximately 2 l of water.
Page 134 Operation Figure 46: Mixer drum – filling Item Designation Aggregate Z Water volume W Binding agent B Aggregate Z1 (Setting up the machine 1. Position the machine correctly P. 4 — 17) . (Start engine P. 5 — 10) . 2.
Page 135: Adjusting The Delivery Air
Operation 13. Fold the hopper back and clean the edge of the dome. 14. Close the drum lid. Allow the machine to continue mixing with the drum lid closed for at least 2 minutes before starting the material delivery cycle. Adjusting the delivery air The delivery air is adjusted using the shut-off valves for header air and delivery air.
Page 136: Delivery
Operation ● The engine is running. ● The mixing apparatus starts up. ● Material is present in the mixer drum. 1. Open the header air valve and the delivery air valve around half‐ way. 2. Start the delivery process. 3. Then adjust the delivery line valve so that the delivery pressure is approx.
Page 137: Enabling Delivery
Operation 6.10.2 Enabling delivery The following requirements must be fulfilled in order to start delivery: ● The safety circuit is closed and acknowledged. ● Material is present in the mixer drum. ● The mixer drum lid is closed. ● The drive motor is running. ●...
Page 138: Setting The Switch-Off Pressure
Operation 6.10.4 Setting the switch-off pressure This switch-off pressure setting is only integrated in combination with a mixer drum lid without automatic venting. For a mixer drum lid with (Setting the switch-off pressure (automatic lid) automatic venting, see P. 6 — 16) . The switch-off pressure specifies the pressure at which material deliv‐...
Page 139: Delivery In Automatic Operation
Operation The switch-off pressure is set using the stop bolt on the automatic venting system. The value can be set between 1 and 4 bar. Figure 50: Pressure cutoff Item Designation Stop bolt Automatic venting system ▶ Use the stop bolt to set the switch-off pressure (maximum 4 bar possible).
Page 140 Operation Figure 51: Control console Item Designation “Pumping functions” selector switch MANUAL – 0 – AUTOMATIC (engage – 0 – tap) 6.10.6.1 Delivery with mechanical lid ▶ Set the “Pumping functions” selector switch to the “AUTOMATIC” position. ⇒ Pressure builds up in the mixer drum and delivery starts auto‐ matically.
Page 141: Interrupting Delivery (Mechanical Lid)
Operation Figure 52: Automatic lid Item Designation Automatic venting system Lever 1. Turn the “Pumping functions” selector switch to position “0”. 2. Push the automatic venting system downwards by the lever and hold it there. ⇒ A proximity switch in the automatic venting system starts the delivery.
Page 142: Interrupting Delivery (Automatic Lid)
Operation Figure 53: Control console Item Designation “Pumping functions” selector switch MANUAL – 0 – AUTOMATIC (engage – 0 – tap) ▶ Turn the “Pumping functions” selector switch to the “Manual” po‐ sition and back to position “0”. ⇒ Delivery is stopped. 6.10.8 Interrupting delivery (automatic lid) You can stop the delivery process at any time.
Page 143: Terminating Delivery
Operation Figure 54: Control console overview Item Designation “Drive motor” selector switch Drive motor OFF – ON – START (engage – engage – tap) ▶ Turn the “Drive motor” selector switch to the “OFF” position. ⇒ The drive motor is switched off. ⇒...
Page 144 Operation Figure 55: Control console Item Designation “Pumping functions” selector switch MANUAL – 0 – AUTOMATIC (engage – 0 – tap) Mixer drum pressure pressure gauge 1. Run the mixer drum completely empty. If you are pumping in automatic operation, you must first select manual operation.
Page 145: Venting The Mixer Drum (Mechanical Lid)
Operation 6.10.10 Venting the mixer drum (mechanical lid) WARNING Risk of injury due to pressure in the mixer drum or delivery line 1. Never forget to open the air vent cock before opening the mixer drum or loosening the delivery line on the drum outlet to dump the pressure in the mixer drum and the delivery line.
Page 146: Venting The Mixer Drum (Automatic Lid)
Operation 6.10.11 Venting the mixer drum (automatic lid) Figure 57: Venting the mixer drum Item Designation Automatic venting system Drum lid Lever Quickrelease lever 1. Terminate the delivery process. ⇒ The pressure in the mixer drum slowly decreases. ⇒ The automatic venting system swings upwards and vents the mixer drum.
Page 147: Eliminating Blockages
Operation ery pressure at the “Mixer drum pressure” pressure gauge rises and the compressor reduces the power requirement at a governed pres‐ sure of 8 bar. Blockages can be prevented. However, they do occur due to: ● Insufficient lubrication of the delivery line, ●...
Page 148 Operation 4. Tap the delivery line to check for hard spots. If the blockage is located at the material outlet (wear connection) of the mixer drum, the delivery line will be soft throughout. If a hard spot in the delivery line is longer than 50 cm, this is cre‐ ated by two blockages with entrapped air in between.
Page 149 Operation After localising the blockage, proceed as follows: 6. Eliminate the blockage ▶ (Eliminating blockages in the delivery line in the delivery line P. 6 — 27) ▶ (Eliminating blockages at the material outlet at the material outlet P. 6 — 27) 6.11.1.1 Eliminating blockages in the delivery line Eliminate a blockage in the delivery line as follows:...
Page 150 Operation WARNING Risk of accident due to material spraying around Material can spray out if the delivery lines and couplings are discon‐ nected while still pressurised. 1. Only disconnect the delivery line when you are certain that the system is depressurised. 2.
Page 151: Mixing Time Extension (Option)
Operation 6.12 Mixing time extension (option) If the mixing time extension option is integrated in your machine, it can be set on the control console. 6.12.1 Setting the remixing time The remixing time is set using the potentiometer on the control con‐ sole.
Page 152: Bluepower
Operation 6.13 BluePower If the BluePower option is integrated in your machine, you can in‐ crease the motor speed on the control console and thereby increase output. The speed is only increased once delivery starts. Figure 60: Control console Item Designation “BluePower”...
Page 153 Operation WARNING Risk of injury due to compressed air 1. Never direct the compressed air towards anyone. 2. Do not use compressed air as breathable air. 3. Do not use compressed air to clean clothing. NOTICE The air tapping coupling does not have a check valve. ▶...
Page 154: Cleaning
Operation 6.15 Cleaning 6.15.1 General At the end of work, the machine and delivery line must be cleaned. A clean machine and delivery line are indispensable to permit fault-free delivery when they are next used. Material deposits and contamination inside the machine and delivery line can impair the function of the machine.
Page 155: Cleaning The Machine
Operation Figure 62: No water in the electrical system 1. In the first six working weeks, clean all painted surfaces with cold water only at a maximum water pressure of 5 bar. Only after this time will the paint have hardened completely, allowing you to use steam jet equipment or similar auxiliary devices.
Page 156 Operation WARNING Risk of injury due to the conveyed material spraying out 1. Wear protective goggles. 2. Open the air vent cock to depressurise the mixer drum, accu‐ mulator and delivery line. 3. Check the pressure gauge indicator to ensure that the mixer drum, accumulator and delivery line are depressurised.
Page 157: Cleaning The Delivery Line
Operation 6.15.3 Cleaning the delivery line Material deposits inside the delivery line can cause damage and can continue to accumulate and thereby reduce the line cross section. To allow faultfree operation at the next use, it is vital that all delivery lines are clean.
Page 158 Operation 2. Vent the mixer drum and open the mixer drum lid (mechanical lid) (Venting the mixer drum (mechanical lid) P. 6 — 23) . ▶ Vent the mixer drum and open the mixer drum lid (automatic lid) (Venting the mixer drum (automatic lid) P. 6 — 24) . 3.
Page 159: Cleaning With A Highpressure Cleaner
Operation (Terminating delivery P. 6 — 21) . 13. Now terminate delivery (Switching off the machine P. 5 — 13) . 14. Switch off the machine 6.15.4 Cleaning with a highpressure cleaner The highpressure cleaner is used to clean the outside of the machine with pressurised water.
Page 160 Operation WARNING Risk of injury and machine damage due to using incorrect media ▶ Never convey explosive or combustible media. NOTICE Damage to electric components and soundproofing equipment of the machine due to high-pressure water ▶ Never direct the water jet at electronic machine components or soundproofing equipment inside the hood.
Page 161 Operation (2) and the high-pressure 2. Connect the high-pressure hose line (1) . 3. Connect the high-pressure hose line of the high-pressure gun to (5) . the high-pressure gun connection (3) between the water mains and 4. Connect a suitable water hose (4) .
Page 162 Operation 8. Press the high-pressure gun trigger and hold it down until water exits the nozzle. This prevents the high-pressure cleaner from drawing in air. 9. Close the hood again. (Start engine P. 5 — 10) . 10. Start the drive motor 11.
Page 163 Operation ⇒ The residual pressure in the high-pressure hose line and the high-pressure gun is dumped. 6 — 41...
Page 164 6 — 42...
Page 165: Faults, Cause And Remedy
Faults, cause and remedy This chapter gives you an overview of faults and their possible cau‐ ses, and also ways in which you may rectify them. Observe the safety regulations when troubleshooting. The inspection and maintenance personnel must have completed training relevant to working with the equipment on the machine and be conversant with the content of the Operating Instructions.
Page 166 7 — 2...
Page 167: General Machine
Faults, cause and remedy General machine The following section provides a description of possible causes of faults and their remedies. 7.1.1 The engine does not start or struggles to start Cause Remedy Ambient temperature too low Use an engine oil grade suitable for the ambient temperature Insufficient fuel in the tank Add fuel...
Page 168: Engine Temperature Too High
Faults, cause and remedy 7.1.3 Engine temperature too high Cause Remedy Ambient temperature too high Switch off the machine Position the machine at a well‐ ventilated location Heat dissipation impeded Remove objects and obstacles in the area where heat is dissi‐ pated Close the hood Engine oil level too low...
Page 169: The Engine Does Not Reach Full Power
Faults, cause and remedy 7.1.5 The engine does not reach full power Cause Remedy Engine oil level too high Reduce the engine oil level Fuel filter dirty or clogged Clean the fuel filter, replace if necessary Incorrect fuel Replace with the correct fuel Dry air filter clogged Clean the filter element, replace if necessary...
Page 170: Engine Consumes Too Much Oil
Faults, cause and remedy 7.1.7 Engine consumes too much oil Cause Remedy Inclination angle of machine ex‐ Align the machine horizontally cessive Engine oil level too high Reduce the engine oil level 7.1.8 The engine is smouldering (blue) Cause Remedy Inclination angle of machine ex‐...
Page 171: The Engine Is Smouldering (Black)
Faults, cause and remedy 7.1.10 The engine is smouldering (black) Cause Remedy Dry air filter clogged Clean the filter element, replace if necessary Dry air filter maintenance indica‐ Have checked and repaired tor defective Charge air line leaking Have checked and repaired Valve play incorrect Have checked and adjusted Injection valve defective...
Page 172: The Engine Starts, But Immediately Stops Again When The "Engine On" Button Is
Faults, cause and remedy 7.1.13 The engine starts, but immediately stops again when the “Engine ON” button is released. Cause Remedy Insufficient fuel in the tank Add fuel Engine oil pressure too low Switch off the machine immedi‐ ately Check the engine oil system (see also the documentation provided by the engine manu‐...
Page 173: Compressor Supply Volume Low, Pressure Excessively High
Faults, cause and remedy 7.1.16 Compressor supply volume low, pressure excessively high Cause Remedy Fine separator cartridge clogged Replace 7.1.17 Excessive compressor oil consumption, oil mist escaping from the discharge valves Cause Remedy Compressor oil level too high Reduce the compressor oil level Incorrect compressor oil grade Replace the compressor oil Fine oil trap defective...
Page 174: Air And Fluid Stream Out Of The Dry Air Filter After The Machine Is Switched Off
Faults, cause and remedy 7.1.19 Air and fluid stream out of the dry air filter after the machine is switch‐ ed off Cause Remedy Incorrect compressor oil grade Replace the compressor oil Check valve of intake control Have replaced valve is leaking 7.1.20 Overheating compressor Cause...
Page 175: Mixing Apparatus Blocked
Faults, cause and remedy 7.1.21 Mixing apparatus blocked Cause Remedy Foreign body in mixer drum Remove the foreign body Mix too dry Remove the material from the mixer drum, clean the mixer drum if necessary, observe the concrete mix proportions for the new mix 7.1.22 Pressure above 5 bar –...
Page 176: Electrical System
Faults, cause and remedy Cause Remedy Blockage at the material outlet Try to clear the blockage by (wear connection) – the delivery quickly venting the mixer drum line is soft throughout. and then restarting the delivery process. Sometimes this is suffi‐ Blockage in the delivery line –...
Page 177: The "Charge Monitor" Indicator Light Does Not Light Up When The Main Switch Is
Faults, cause and remedy 7.2.1 The “Charge monitor” indicator light does not light up when the main switch is switched on. The machine cannot be started. Cause Remedy Flat or defective battery Check the electrolyte level and charge the battery, have re‐ placed if necessary Loose battery connection or oxi‐...
Page 178: The Starter Does Not Crank The Engine When The "Engine Selector Switch" Is Actuated
Faults, cause and remedy 7.2.4 The starter does not crank the engine when the “Engine selector switch” is actuated Cause Remedy Low battery power Check the electrolyte level and charge the battery, have re‐ placed if necessary “Engine selector switch” defec‐ Check, have replaced if neces‐...
Page 179 Faults, cause and remedy 7.2.7 The engine starts, but the “Engine oil pressure/engine oil tempera‐ ture” indicator light is still lit. The compressor stops again when the “Engine selector switch” is released. Cause Remedy AC generator/controller defec‐ Have checked and repaired tive 7.2.8 Compressor switched off automatically, “Engine oil pressure/engine...
Page 180 Faults, cause and remedy NOTICE Risk of machine damage due to incorrect assembly and setting up ▶ Only have the assembly and setting up of the axle and wheels carried out by a subject expert authorised by Putzmeister Mör‐ telmaschinen GmbH or a qualified specialist workshop. For information on the causes of faults and their remedies, refer al‐...
Page 181 Faults, cause and remedy 7.3.3 To much play between ball hitch and ball, risk of disconnecting Cause Remedy Ball on tractor unit worn, ball di‐ Replace the ball. ameter smaller than 49 mm. The diameter of the ball on the tractor unit must be between 50 mm and 49 mm (DIN 74058) when new.
Page 182 Faults, cause and remedy 7.3.5 Unbalanced driving behaviour and jerky braking Cause Remedy Shock absorber defective. Have checked and set/rectified by a specialist workshop. Too much play in the braking Have the braking system system. checked and set/rectified by a specialist workshop.
Page 183 Faults, cause and remedy Cause Remedy Crank lever jammed. Have checked and set/rectified by a specialist workshop. Linkage bracket bent. Wheel brake contaminated. (Bowden) cable kinked. Return springs are sluggish or broken. Rust formation in the brake drum. 7.3.8 Parking brake too weak Cause Remedy Pneumatic spring defective.
Page 184 Faults, cause and remedy 7.3.9 Reverse travel is sluggish or not possible Cause Remedy Braking system set too tightly. Have the braking system checked and set/rectified by a Automatic reverse lever is jam‐ specialist workshop. med. 7.3.10 The height adjustment of the overrunning brake equipment is too sluggish Cause Remedy...
Page 185: Fault Messages And Warnings
Faults, cause and remedy Fault messages and warnings Symbol Message Remedy (Overheating com‐ Compressor temperature pressor P. 7 — 10) The engine shuts down immediately in the event of excess temperature of the compressor. The LED lights up in red. The display background turns red and the symbol is shown.
Page 186 Faults, cause and remedy Symbol Message Remedy (No or insufficient oil Engine oil pressure pressure in the en‐ The engine oil pressure is gine P. 7 — 5) checked approx. 5 sec‐ onds after start-up. If the oil pressure is not reached, the engine is switched off.
Page 187 Faults, cause and remedy Symbol Message Remedy Battery charge state The battery must be charged. The battery charge state is too low. The engine is not switched off and it may not be possible to restart it. The LED lights up in yel‐ low.
Page 188 Faults, cause and remedy Symbol Message Remedy Safety circuit open The EMERGENCY STOP button must The safety circuit was be unlocked or the opened. This occurs when protective grille the EMERGENCY STOP must be closed. button is actuated or the protective grille is opened.
Page 189: Maintenance
Maintenance In this chapter you will find information on maintenance work which is necessary for the safe and efficient operation of the machine. We would like to explicitly emphasise here that all prescribed checks, inspections and preventative maintenance work must be conscien‐ tiously carried out.
Page 190 8 — 2...
Page 191 Maintenance Maintenance and inspection by the machine oper‐ ator Regular preventative inspections allow you to detect machine dam‐ age well in advance and implement the necessary repair measures. See the “Maintenance intervals” section for information on the type and frequency of necessary inspection work. It is recommended that the details and results of the inspections are documented in a suitable format.
Page 192 Maintenance WARNING Risk of injury due to not wearing personal protective equipment ▶ Always wear your personal protective equipment during mainte‐ nance work. 8.2.2 Personnel requirements Only qualified personnel may carry out maintenance work. Qualified personnel must have successfully completed a specialist training course that qualifies them to carry out such activities.
Page 193 Maintenance WARNING Risk of burning due to hot functional fluids and surfaces (e.g. engine and frame) 1. Allow hot functional fluids and surfaces to cool first. 2. Always wear personal protective equipment. 3. Cover hot surfaces with heatresistant materials. WARNING Risk of injury by shearing, being drawn in and crushing when raising or lowering the mixer equipment ▶...
Page 194: Maintenance Intervals
Maintenance WARNING Risk of injury due to hydraulic fluid spraying out Injuries to the skin and eyes can be caused by hydraulic fluid spray‐ ing out when opening threaded unions. ▶ Dump the pressure in the entire hydraulic system before open‐ ing threaded unions.
Page 195 Maintenance General machine Action every ... operating hours Comments daily once af‐ 1000 Other inter‐ Reference ter 50 vals Visual inspection: Defects ✓ ✓ Rectify the de‐ and leak tightness (leaks) fects, establish leak tightness (eliminate leaks) Check the fastening bolts ✓...
Page 196 Maintenance Safety equipment Action every ... operating hours Comments daily once af‐ 1000 Other inter‐ Reference ter 50 vals Check whether the EMER‐ ✓ GENCY STOP button is fully functional Check whether the safety ✓ Have replaced or equipment is fitted and fully repaired if neces‐...
Page 197 Maintenance Drive motor Action every ... operating hours Comments daily once af‐ 1000 other inter‐ Reference ter 50 vals Check the dry air filter dust ✓ ✓ Clean if necessa‐ (Cleaning the discharge valve weekly dust discharge valve P. 8 — 30) Check the fuel level ✓...
Page 198 Maintenance Drive motor Action every ... operating hours Comments daily once af‐ 1000 other inter‐ Reference ter 50 vals Check and adjust the injec‐ ✓ Service tion valves 3000 h Check the valve play and ✓ Service adjust 1000 h, at least annually Replace the toothed belt ✓...
Page 199 Maintenance Compressor Action every ... operating hours Comments daily once af‐ 1000 other inter‐ Reference ter 50 vals Clean the fluid/compressed ✓ air radiator 1500 h, at least annually Check the pressure hoses ✓ for leaks and wear 1500 h, at least annually Safety valve function check ✓...
Page 200 Maintenance Hydraulic system Action every ... operating hours Comments daily once af‐ 1000 Other inter‐ Reference ter 50 vals Hydraulic hose lines: Visual ✓ ✓ annually Do not repair, re‐ inspection for ageing, leak place immediate‐ tightness (leaks) and dam‐ ly if damaged age.
Page 201 Maintenance Mixer drum (depending on model) Action every ... operating hours Comments daily once af‐ 1000 Other inter‐ Reference ter 50 vals (Lubricating the Lubricate the mixer drum ✓ machine weekly P. 8 — 22) De‐ tail C + D Check the mixer shaft bear‐...
Page 202 Maintenance Highpressure cleaner (option) Action every ... operating hours Comments daily once af‐ Other inter‐ Reference ter 50 vals Check the highpressure ✓ See the “Mainte‐ cleaner fluid level, top up if nance work” sec‐ necessary tion Highpressure cleaner anti‐ ✓...
Page 203 Maintenance Axle and wheels (depending on model) Action daily every annually Other inter‐ Comments 10,000 km vals Reference Request service engineers ✓ once after Service 500 km Have the fastening bolts tightened by service engi‐ neers Support wheel – check for ✓...
Page 204 Maintenance Axle and wheels (depending on model) Action daily every annually Other inter‐ Comments 10,000 km vals Reference Ball hitch – have the en‐ ✓ ✓ Service gagement indicator checked Clean and lubricate/grease ✓ ✓ the ball hitch Have the ball hitch checked ✓...
Page 205 Maintenance Axle and wheels (depending on model) Action daily every annually Other inter‐ Comments 10,000 km vals Reference Towing gear – check, clean ✓ ✓ and lubricate/grease the toothed discs Check the parking brake for ✓ full movement, have re‐ paired by service engineers if necessary Have the parking brake...
Page 206: Maintenance Work
Maintenance Maintenance work In this section you will find all maintenance work for this machine. 8.4.1 Preliminary work for maintenance work Various components on the machine can be swung out of the way or removed in a few steps to facilitate maintenance work. References to the following sections can be found in the relevant maintenance de‐...
Page 207 Maintenance Item Designation Cable harness Spring bolt NOTICE Damage to the cable harness when folding down the control cabinet ▶ Unplug the connector for the cable harness from the control cabinet before folding down the control cabinet. (Switching off the engine P. 5 — 12) . 1.
Page 208 Maintenance 8.4.1.2 Removing and fitting the control console Figure 68: Control console Item Designation Control console Connector Bolts Removal: (Switching off the machine P. 5 — 13) . 1. Switch off the machine 2. Unplug the connector from the control console. 3.
Page 209 Maintenance 9. Tighten the bolts (3 pieces). 10. Insert the hose on the rear of the pressure gauge. 11. Plug in the connector at the control console. 12. Check the alignment of the control console with the hood and align the control console with the hood as required. 8.4.1.3 Swinging the centralised lubrication system to maintenance position The centralised lubrication system is mounted on a pivoting device.
Page 210 Maintenance 8.4.2 Lubricating the machine The following overview shows the lubrication points on the machine. The following special tools are required: ● Grease gun Use only lubricants specified in the lubricant recommendation (see the “Appendix” chapter). The specified lubrication interval applies to normal operation. Un‐ der extreme conditions of use, more frequent lubrication may be necessary.
Page 211 Maintenance Item Designation Protective grille bearing, detail C Lid vent (lubricate with the lever open), detail C Lid hinge, detail C Hopper hinge (D/DB), detail B Hydraulic cylinder – bolt on the bottom of the loading hopper device (DB/DBS), detail A Bottom release lever bearing;...
Page 212 Maintenance Figure 71: Detailed illustration of lubrication points 1. Remove the protective cap from the lubrication point. 2. Clean the lubrication nipple. 8 — 24...
Page 213 Maintenance 3. Lubricate until fresh grease escapes. 4. Remove the excess grease from the lubrication nipple. 5. Place the protective cap over the lubrication point. 8.4.3 Changing the engine oil and engine oil filter Replace the engine oil filter when you change the engine oil. Change the engine oil when the engine is warm after operation.
Page 214 Maintenance Figure 72: Changing the engine oil and engine oil filter Item Designation Oil filler lid Oil dipstick Engine oil filter Oil drain valve Base plate 1. Align the machine horizontally. (Switching off the engine P. 5 — 12) . 2.
Page 215 Maintenance 10. Screw in the new engine oil filter by hand until it is flush with the gasket. Observe the information on the engine oil filter. 11. Tighten the engine oil filter another half turn. 12. Unscrew the access cover from the oil drain valve. 13.
Page 216 Maintenance 8.4.4 Cleaning and changing the dry air filter This section describes how to clean the drive motor dry air filter and how to replace the filter element. The filter element must be cleaned/replaced if the red area is visible in the window of the maintenance indicator or if the maintenance in‐...
Page 217 Maintenance NOTICE Risk of machine damage due to damaged or clogged filter element. 1. A damaged filter element must be replaced and must not be fit‐ ted again. 2. The blow-out pressure must not exceed 5 bar during cleaning. 3. An appropriate distance must be maintained between the hose nozzle and the filter element during cleaning.
Page 218 Maintenance 5. Check the filter element. If it is damaged, check all connections on the dry air filter and replace the damaged parts. 6. Place the filter lid back on the filter housing during cleaning to protect the air intake system. 7.
Page 219 Maintenance 8.4.4.3 Resetting the maintenance indicator Figure 75: Resetting the maintenance indicator Item Designation Maintenance indicator Reset button for the maintenance indicator ▶ (1) after cleaning or changing Reset the maintenance indicator (2) to do so. the filter element. Press the reset button 8.4.5 Cleaning the air valve WARNING...
Page 220 Maintenance Figure 76: Air valve fitting Item Designation Check valves Air line (flotation air line) Air line (header air line) Air valve (header air line) Air valve (flotation air line) 8 — 32...
Page 221 Maintenance 8.4.5.1 Cleaning the air line Figure 77: Cleaning the air line Item Designation Putzmeister coupling Air line (header air/flotation air line) (2) from the mixer drum. 1. Disconnect the air line 2. Clean the air line and coupling thoroughly. Replace the air line if extremely dirty.
Page 222 Maintenance 8.4.5.2 Cleaning the check valves Figure 78: Cleaning the check valves Item Designation Check valve Screw plug Insert (obscured) 1. Unscrew the screw plug of the check valve . 2. Remove the insert from the check valve. 3. Clean the insert thoroughly. 4.
Page 223 Maintenance 8.4.6 Checking the hydraulic fluid level WARNING Risk of injury due to hot hydraulic fluid or hydraulic fluid spraying out 1. Check the hydraulic fluid level with the machine horizontal and supported. 2. Only check the hydraulic fluid with the machine shut down. 3.
Page 224 Maintenance Figure 79: Hydraulic fluid reservoir Item Designation Fill level indicator Oil filler 1. Check the hydraulic fluid level at the fill level indicator. The indi‐ cator must be between the MIN and the MAX marking. 2. Top up the hydraulic fluid if necessary. 8.4.7 Changing the hydraulic fluid The hydraulic fluid fill volumes can be found in the “Technical data”...
Page 225 Maintenance NOTICE Environmental pollution due to hydraulic fluid escaping 1. Collect the old hydraulic fluid. 2. Avoid spilling the old hydraulic fluid. 3. Separate the collected hydraulic fluid and the used filter ele‐ ments from other waste. 4. Dispose of the collected hydraulic fluid and the used filter ele‐ ments in line with the relevant national and regional regulations.
Page 226 Maintenance Figure 80: Hydraulic fluid reservoir Item Designation Fill level indicator Oil filler Oil drain cock Oil drain plug 1. Place a sufficiently large oil drain pan under the machine. 2. Carefully unscrew the oil drain plug. 3. Open the oil drain cock carefully and allow the used oil to drain into the oil catch pan.
Page 227 Maintenance 13. Top up the hydraulic fluid level as required. 8.4.8 Checking and replacing the hydraulic hose lines This section describes how to check and replace the hydraulic hose lines. The inspection intervals can be found in the “Maintenance inter‐ vals”...
Page 228 Maintenance WARNING Risk of burning from hot machine components ▶ Allow the assemblies to cool down before you start the work. 8.4.8.1 Checking the leak tightness of the hydraulic hose lines 1. Switch off the machine. 2. Check whether all pressures in the hydraulic system and in the delivery line have fallen to 0 bar before commencing the work.
Page 229 Maintenance You may only tighten leaking flared screwed joints with the permit‐ ted tightening torque. Tighten the threaded union until you clearly feel an increase in the force required if you do not have a torque wrench available. You must replace these flared screwed joints if the leaks persist.
Page 230 Maintenance 8.4.8.3 Replacing hydraulic hose assemblies CAUTION Risk of injury from being struck by hydraulic hose assemblies Hydraulic hose assemblies may be mechanically prestressed. ▶ Check for any prestressed lines. 1. Switch off the machine. 2. Check whether the pressure in the hydraulic system has dropped to 0 bar before you start the work.
Page 231 Maintenance 11. Check the hydraulic functions in several test runs. Check the leak tightness of the hydraulic system and top up with hydraulic fluid as required. 12. Check all hydraulic hose assemblies again. 13. Refit all the safety equipment, markings and information plates you have removed.
Page 232 Maintenance 8.4.9.1 Removing light contamination on the radiator The machine is equipped with a radiator cleaning function. The fan can be operated in reverse with a button. This causes light contami‐ nation to be extracted out of the radiator. Figure 83: Reverse fan operation Item Designation Button (reverse fan operation)
Page 233 Maintenance Figure 84: Front faceplate Item Designation Front faceplate Bolts (12 pieces) 1. Remove the front faceplate (12 bolts). 2. Wash out the cooling fins with water against the direction of the air flow. Use a water hose with suitable nozzle and a water pressure of max. 4 bar.
Page 234 Maintenance WARNING Risk of injury due to compressor oil spraying out 1. Only carry out a compressor oil/oil filter change when the en‐ gine is shut down and the compressor is depressurised. 2. Only open the filler pipe once the pressure has been fully dum‐ ped.
Page 235 Maintenance Item Designation Bolts (3 pieces) Maintenance lid 1. Switch off the drive motor. 2. Open the motor compartment hood. 3. Switch off the machine at the main switch and secure the main switch to prevent restarting. 4. Place a sufficiently large oil drain pan under the machine. 5.
Page 236 Maintenance Pay attention to the flattened side of the maintenance lid when insert‐ ing it. This flattened side must be in the correct position when insert‐ ing the lid (see arrow). Once it is in the correct position, the oil chan‐ nel on the interior of the maintenance lid will be aligned with the oil bore in the compressor housing.
Page 237 Maintenance Only top up the oil level to the “Maximum” marking. An excess of oil results in increased oil consumption. 5. Check the maintenance lid for leak tightness. 6. Rectify any leaks that may be present. 8.4.11 Changing the air/oil separator WARNING Risk of injury due to compressor oil spraying out Injuries to the skin and eyes due to compressor oil spraying out...
Page 238 Maintenance Figure 86: Changing the air/oil separator Item Designation Compressor Air/oil separators 1. Switch off the drive motor. 2. Open the motor compartment hood. 3. Switch off the machine at the main switch and secure the main switch to prevent restarting. 4.
Page 239 Maintenance 8.4.12 Compressor – checking the oil level WARNING Risk of scalding due to compressor oil spraying out 1. Only open the oil filler once the pressure has been fully dum‐ ped. 2. Only correct the compressor oil level when the machine is cold. NOTICE Technical damage due to incorrect measurement of the compressor oil level...
Page 240 Maintenance Figure 87: Checking the compressor oil level Item Designation Screw plug (oil filler) Oil level inspection glass 1. Open the motor compartment hood. 2. Check the compressor oil level at the oil level inspection glass of the compressor. ⇒ You must top up the compressor oil if you cannot see any compressor oil in the oil level inspection glass.
Page 241 Maintenance NOTICE Technical damage due to contamination of the compressor air inlet Dirt and dust particles can enter the air inlet of the compressor through the compressor air intake. 1. Change the air filter element regularly. 2. Never clean the air filter element. Replace the air filter element if it is contaminated.
Page 242 Maintenance 5. Carefully pull the filter element out of the filter housing. Avoid dust falling out as much as possible while doing so. 6. Carefully remove the dust from the filter housing and filter lid. 7. Insert the new filter element into the filter housing. 8.
Page 243 Maintenance 8.4.14 Checking the safety valve The safety valve must be vented annually to remove stubborn con‐ tamination particles. DANGER Danger due to manipulation of the safety valve 1. Never damage or remove the seal on the safety valve. 2. Never change the blow-off pressure of the safety valve. 3.
Page 244 Maintenance Figure 90: Safety valve Item Designation Knurled nut Safety valve Ideally, carry out the safety valve inspection immediately after switch‐ ing off the machine as the system pressure will still be present. 1. Switch off the machine. Refer also to the “Shutting down the ma‐ chine after starting up”...
Page 245 Maintenance 8.4.15 Changing the fuel filter The following special tools are required: ● Filter wrench DANGER Risk of fire, risk of explosion due to escaping fuel 1. Allow the assemblies to cool down first. 2. Refrain from working with naked flames and from smoking. 3.
Page 246 Maintenance Figure 91: Fuel filter Item Designation Fuel line filter Fuel filter Fuel pump Fuel screen filter 8.4.15.1 Changing the fuel filter 1. Remove the fuel filter with a filter wrench. 2. Collect the fuel from the filter and dispose of the fuel filter in ac‐ cordance with regulations.
Page 247 Maintenance 4. Raise the ends of the hoses to prevent fuel from escaping from the fuel line. 5. Attach the new fuel line filter to the hoses. Pay particular attention to the flow direction. 6. Retighten the hose clamps. 8.4.15.3 Cleaning/replacing the fuel screen filter 1.
Page 248 Maintenance 8.4.16 Drain the fuel filter (with water-separating filter) Figure 92: Draining the fuel filter Item Designation Drain plug Fuel filter (Switching off the machine P. 5 — 13) . 1. Switch off the machine 2. Open the hood. 3. Hold a suitable container under the drain plug on the fuel filter. 4.
Page 249 Maintenance 8.4.17 Centralised lubrication system – checking the fill level Figure 93: Centralised lubrication system Item Designation Lubricant reservoir Lubrication nipple Lubricant reservoir filling point The centralised lubrication system supplies the two lubrication points on the mixer shaft with sufficient grease. The lubricant reservoir is filled on the lubricant reservoir filling point or the lubrication nipple.
Page 250 Maintenance 8.4.18 Changing the mixing apparatus drive belt Figure 94: Mixing apparatus drive belt Item Designation Drive belt Cover Bolt Bolt WARNING Risk of injury by shearing or being drawn in on the running drive belt Drawing in and shearing of body parts like fingers and hands on the running drive belt.
Page 251 Maintenance 6. Remove the drive belt from the pulleys and take it out of the mo‐ tor compartment. 7. Fit the new drive belt by following these steps in reverse order. 8.4.19 Changing the generator drive belt Figure 95: Generator drive belt Item Designation Drive belt...
Page 252 Maintenance 4. Remove the cover. (2) . 5. Unscrew the bolt (3) downwards. 6. Swing the generator (1) from the pulleys and take it out of the 7. Remove the drive belt motor compartment. (1) by following these steps in reverse or‐ 8.
Page 253 Maintenance Figure 96: Checking the bolted connections between the mixer drum and the frame Item Designation Bolted connections between the mixer drum and the frame (four) DANGER Risk of injury due to the mixer drum detaching from the frame 1. Check that the bolted connections between the mixer drum and the frame are firmly seated after 50 operating hours.
Page 254 Maintenance 4. If the mixer drum is detached from the frame for repairs, always use new bolts and self-locking nuts. 8.4.21 Replacing the mixing paddles in the mixer drum WARNING Risk of injury due to unauthorised or accidental starting up of the machine Very serious injuries can be sustained when working inside the mix‐...
Page 255 Maintenance Figure 98: Replacing the mixing paddles, different models available Item Designation Selflocking hexagon nut Washer Clamping piece for mixing paddle Mixing blade holder Hexagon head bolt for mixing paddle Mixing paddle (different models) Hexagon head bolt for mixing blade holder Washer Selflocking hexagon nut The mixing paddles can also be replaced with the mixing blade...
Page 256 Maintenance Figure 99: Mixing paddle and mixing blade holder dimensions Position Dimension 126 mm 126 mm 90 mm 15 ± 2 mm The mixing paddles in the mixer drum have different designs. NOTICE Technical damage due to incorrect arrangement of mixing paddles on the mixer shaft.
Page 257 Maintenance 6. If necessary, fit the mixing blade holders with new selflocking hexagon nuts back onto the mixer shaft, observing the specified distances. 7. Check the distance between the mixing paddles and the wear plates (dimension X) and adjust it if necessary. 8.
Page 258 Maintenance Item Designation Mixer shaft Mixing blade holder 1. Open the drum lid at the filling dome. 2. Open the protective grille. 3. Remove all mixing blade holders from the mixer shaft. Figure 101: Wear plates Item Designation Selflocking domed nut Sealing ring Countersunk screw Wear plates...
Page 259 Maintenance 6. Bolt down the wear plates with new domed nuts, sealing rings and countersunk screws. 7. Check the mixing paddles for damage or wear and replace them (Replacing the mixing paddles in the mixer drum if necessary P. 8 — 66) . NOTICE Technical damage due to worn or incorrectly fitted mixing paddles on the mixer shaft...
Page 260 Maintenance Figure 102: Checking the protective grille wear 1. Check the protective grille wear every day. 2. Measure the width (B) and height (H) of the grille rods in the area subject to the most wear, preferably in the centre of the hopper grille.
Page 261 Maintenance 2. Secure the machine against rolling away or toppling over. 3. Engage the handbrake. 4. Place the chocks in position. 8.4.24.2 Drawgear disassembly Figure 103: Drawgear Item Designation Ball hitch Nuts (self-locking) Cable ties Rubber gaiter Fastening bolts Towing ring 1.
Page 262 Maintenance 8.4.24.3 Drawgear assembly 1. Position another drawgear. (Not included in scope of supply.) Figure 104: Drawgear Item Designation Ball hitch Nuts (self-locking) Cable ties Rubber gaiter Fastening bolts Towing ring WARNING Risk of injury due to drawgear tearing off due to incorrectly fitted fastening bolts ▶...
Page 263 Maintenance 4. Tighten them with the correct tightening torque as specified in the table. 5. Place the protective caps over the nuts. The model and version are marked on the drawgear. Towing ring tightening torques Type Version Number of Bolt dimen‐ Tightening bolts sions...
Page 264 Maintenance 8.4.25 High-pressure cleaner – checking the fluid level 8.4.25.1 Checking the fluid level Figure 105: Example illustration of the high-pressure cleaner Item Designation Highpressure cleaner Inspection glass Vent connection (1) on the in‐ 1. Check the fluid level of the high-pressure cleaner (2) .
Page 265 Maintenance 8.4.26 Highpressure cleaner – antifreeze protection If there is a risk of freezing, the water in the highpressure cleaner and lines may freeze and cause assemblies to burst. WARNING Machine damage due to freezing water in the high-pressure pump Freezing temperatures can cause the water in the highpressure cleaner and lines to freeze and result in assemblies bursting.
Page 266 Maintenance 6. Close the ball valve again once the residual water has completely drained from the highpressure cleaner and the lines. 7. Disconnect the highpressure hose. 8. Check the change-over valve. The lever must be in the “Loader” position. Functional fluids The manufacturer accepts no liability for damage caused by using unauthorised functional fluids.
Page 267 Maintenance 8.5.1 Fuel WARNING Risk of injury due to fuel igniting Smoking is absolutely prohibited when fuelling. 1. Fill the machine with fuel only when the engine is switched off. 2. Keep a fire extinguisher readily available while fuelling. 3. Never fill the fuel tank near naked flames or ignitable sparks. 4.
Page 268 Maintenance 8.5.3 Gearbox oil NOTICE Risk of machine damage due to incorrect gearbox oil 1. Only use a gearbox oil in accordance with the requirements standard specified in the lubricant recommendation for topping up or performing a full oil change. Observe the manufacturer’s information in doing so.
Page 269 Maintenance NOTICE Risk of machine damage due to incorrect hydraulic fluid 1. Only use hydraulic fluid in accordance with the requirements standard specified in the lubricant recommendation for topping up or performing a full fluid change. Observe the manufacturer’s information in doing so. 2.
Page 270 8 — 82...
Page 271 Decommissioning This chapter contains information on decommissioning the machine. 9 — 1...
Page 272 9 — 2...
Page 273: Temporary Decommissioning
Decommissioning Temporary decommissioning If the machine will be shut down or stored, it must be lubricated and, if needed, preserved. Preserving and lubricating the machine protects it against corro‐ sion and rapid ageing. This is required if the machine: ● Will be shut down for a longer period, ●...
Page 274 Decommissioning 5. Preserve the machine with a suitable agent. Filling up the fuel tank Fill up the fuel tank when work is completed. This prevents excessive condensation building up in the tank. NOTICE Risk of machine damage due to incorrect fuel Not using low-sulphur diesel fuel will damage the diesel particle fil‐...
Page 275: Antifreeze Protection
Decommissioning Antifreeze protection NOTICE Damage to the machine caused by freezing water ▶ If there is a risk of freezing, you must drain the machine and the delivery line fully of residual water. Final decommissioning and disposal The final decommissioning and disposal requires the complete disas‐ sembly of the machine into its individual components.
Page 276 Decommissioning NOTICE Environmental pollution caused by incorrect disposal of the machine 1. When disposing of all machine components, ensure that there is no possibility of damage to health or the environment. 2. Commission a qualified specialised company with the final dis‐ posal of the machine.
Page 277 Decommissioning Designation Applies for Electronic scrap Electrical supply PCBs with electrical compo‐ nents Highpressure cleaner Hydraulic pump Hydraulic motor Drive motor Compressor 9 — 7...
Page 278 9 — 8...
Page 279 Appendix This chapter contains the following topics: ● Lubricant recommendation ● Sample of the EC Declaration of Conformity Depending on the machine model, further documents may be inclu‐ ded in the appendix. 10 — 1...
Page 280 10 — 2...
Page 281: Lubricant Recommendation
Appendix 10.1 Lubricant recommendation We have listed all suitable lubricants and hydraulic fluids for your ma‐ chine in the tables below. NOTICE Risk of machine damage caused by mixing oils 1. The manufacturer accepts no liability for damaged caused by mixing oils from different manufacturers.
Page 282 Appendix Engine oil Marking as per DIN 51502 Requirements standard API CD Characteristics mineral Viscosity SAE 10W-40 (DIN 51511) Putzmeister order no. 487039 Gearbox oil Standard Winter Marking as per DIN 51502 Requirements API GL4 standard Characteristics mineral Viscosity SAE 90 (DIN 51512) SAE 80 (DIN 51512) Putzmeister 487039...
Page 283 Appendix Greases Lubrication (man‐ Centralised lubri‐ ual) cation system Marking as per DIN K2K-25 51502 Requirements standard DIN 51825 Characteristics mineral, lithium soap NLGI Class 2 NLGI Class DIN 51818 Container 400 g 18 kg Part number 000113007 000174004 Highpressure cleaner (option) Type CLP 100 Characteristics...
Page 284 Appendix 10.2 Sample EC Declaration of Conformity The original EC Declaration of Conformity is included in the ma‐ chine's scope of supply. Keep it in a safe place. 10 — 6...
Page 285 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. Centralised lubrication system – checking the fill level P.
Page 286 Index P. 5 — 7 P. 2 — 23 Checking the reservoir wall thickness Conduct in an emergency P. 8 — 55 P. 3 — 16 Checking the safety valve Control cabinet P. 5 — 6 P. 3 — 17 Checking the wear plates Control console P.
Page 287 Index P. 6 — 27 P. 3 — 1 Eliminating blockages at the material outlet General technical description P. 6 — 27 P. 8 — 81 Eliminating blockages in the delivery line General tightening torques for bolts P. 6 — 3 P.
Page 288 Index P. 2 — 6 Operation with defects P. 3 — 3 P. 2 — 3, 2 — 24 Machine model Operator P. 2 — 3 P. 3 — 11 Machine operator Options P. 2 — 4, 8 — 1 P.
Page 289 Index P. 3 — 10 P. 6 — 29 Rating plate Setting the remixing time P. 6 — 16 Relevant legal foundations for compressed air convey‐ Setting the switch-off pressure P. 2 — 10 P. 6 — 16 Setting the switch-off pressure (automatic lid) P.
Page 290 Index The “Charge monitor” indicator light does not light up The starter cranks the engine when the “Engine selector when the main switch is switched on. The machine can‐ switch” is actuated. The engine does not start. P. 7 — 13 P.
Page 292 Brinkmann Eine Marke der Putzmeister Gruppe Max–Eyth–Straße 10 72631 Aichtal Tel.: +49 7127 599-0 Service-Hotline: +49 7127 599-699 Fax: +49 7127 599-743 E-Mail: info@estrichboy.de Web: www.estrichboy.de...

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