manual operating & maintenance instructions bsf 36-4.12l

Operating Instructions

BSF 36-4.12L210603466

A820062 E

Table of contents

IINHV

1 Guide to the Operating Instructions 1–1.

1.1 Foreword 1–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 Icons and symbols 1–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 Safety Regulations 2–1. . . . . . . . . . . . . . .

2.1 Personnel Qualifications 2–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2 Safety Regulations 2–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 Use contrary to the designated use 2 — 5. . . . . . . . . . . . . . . . . . . 2.3.1 Lifting loads 2 — 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.2 Extending the end hose 2 — 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.3 End hose with spout 2 — 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.4 Extending the reach 2 — 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.5 Standing on the placing boom 2 — 8. . . . . . . . . . . . . . . . . . . . . . . . . 2.3.6 Exclusion of liability 2 — 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 General Technical Description 3–1. . . . .

3.1 36Z Overview Diagram 3–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 Technical Data 3–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 Machine Rating Plate 3–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4 Boom Rating Plate 3–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5 36Z Range Diagram 3–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6 Description of the Functions 3–6. . . . . . . . . . . . . . . . . . . . . . . . . 3.6.1 Boom 3–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6.2 Delivery Line 3–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6.3 Outriggers 3–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6.4 Hydraulic Control 3–6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6.5 Concrete Pump 3–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6.6 S Transfer Tube 3–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.7 Symbols for the Control System 3–8. . . . . . . . . . . . . . . . . . . . . . 3.7.1 Concrete Pump (Part 1) 3–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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3.7.2 Concrete Pump (Part 2) 3–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7.3 Engine 3–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7.4 Electrical System (Part 1) 3–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7.5 Electrical System (Part 2) 3–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7.6 Hydraulic System 3–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7.7 Outriggers 3–13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7.8 Boom 3–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.8 Electrical Control Devices 3–15. . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8.1 Central Module Control Cabinet 3–16. . . . . . . . . . . . . . . . . . . . . . . . 3.8.2 Control Panel in the Steps 3–21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8.3 Cable Remote Control 3–26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8.4 Radio Remote Control 3–28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8.5 EMERGENCY SHUT-DOWN Button 3–34. . . . . . . . . . . . . . . . . . . 3.8.6 Proximity Switch Junction Box 3–36. . . . . . . . . . . . . . . . . . . . . . . . . 3.8.7 Proximity Switch Connector 3–38. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8.8 Hopper Grate Cutout Device 3–39. . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8.9 Agitator Shut-Off Valve 3–41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.9 Hydraulic Control Devices 3–42. . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9.1 Outriggers Control Block 3–43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9.2 Boom Functions Control Block 3–44. . . . . . . . . . . . . . . . . . . . . . . . . 3.9.3 Agitator Lever 3–45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9.4 Water Pump Lever 3–46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9.5 Accumulator Dump Valve, Accumulator Dump Cock,

Transfer Tube Damping Cock 3–47. . . . . . . . . . . . . . . . . . . . . . . . . . 3.9.6 Manual Volume Control 3–49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.10 Other Components 3–50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10.1 Flushing Water Pump 3–50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10.2 End hose 3–51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10.3 Vibrator 3–54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10.4 Hydraulic Fluid Radiator 3–55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 Travel 4–1. . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 Driving 4–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.1 Prior to Driving 4–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.2 Driving in Reverse 4–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.3 During the Journey 4–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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4.2 Towing 4–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3 Loading 4–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 Operation 5–1. . . . . . . . . . . . . . . . . . . . . . .

5.1 Preliminary Information 5–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 Function Checks 5–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2.1 Pump Functions 5–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Switchover 5–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Proximity Switch 5–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stroke Length 5–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stroke Time 5–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.2 Filter Functions 5–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vacuum Filter 5–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Boom Filter 5–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.3 EMERGENCY SHUT-DOWN Function 5–5. . . . . . . . . . . . . . . . . . EMERGENCY SHUT-DOWN Button 5–6. . . . . . . . . . . . . . . . . . .

5.2.4 Function Check on the Boom Control Unit 5–6. . . . . . . . . . . . . . .

5.3 Setup 5–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.1 Pre-Operation Inspection 5–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.2 Preliminary Setup 5–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Calculation Example 1 5–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Calculation Example 2 5–11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Corner Bearing Load 5–14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Support Block 5–15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Length of the Timber Blocks Required 5–16. . . . . . . . . . . . . . . . . .

Example 1 5–17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Example 2 5–18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3.3 Remote Control Setup 5–20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.4 Outriggers Setup 5–23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4 Boom Movements 5–27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Prohibited Activities 5–27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overlapping Working Ranges 5–27. . . . . . . . . . . . . . . . . . . . . . . . . .

5.4.1 Restrictions on Use 5–28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bad Weather and Storms 5–28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cold Weather 5–28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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5.4.2 Danger Zone 5–29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4.3 High-Voltage Lines 5–30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4.4 Signal of Boom Movements 5–31. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4.5 Temperature-Related Cylinder Movements 5–31. . . . . . . . . . . . . . 5.4.6 Uncontrolled Boom Movements 5–32. . . . . . . . . . . . . . . . . . . . . . . .

Countermeasures 5–32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5 Hand Signals for Boom and Pumping Operations 5–33. . . . . .

5.6 Extending the 36Z 4-Section Boom 5–34. . . . . . . . . . . . . . . . . . . 5.6.1 Impermissible Working Range 5–39. . . . . . . . . . . . . . . . . . . . . . . . .

5.7 Pumping Operations 5–40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7.1 Hazards 5–40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7.2 Notes on Correct Pumping 5–42. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7.3 Starting Pumping 5–44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7.4 Pumping 5–44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7.5 Possible Faults 5–46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Blockages 5–46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overheating 5–47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Restarting After Overheating 5–48. . . . . . . . . . . . . . . . . . . . . . . . . . .

5.7.6 Special Cases 5–49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Continuation Delivery Line 5–49. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.8 Cleaning 5–50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8.1 Preparations for Cleaning 5–50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8.2 Delivery Line Cleaning Methods 5–56. . . . . . . . . . . . . . . . . . . . . . . . 5.8.3 Delivery Line Suction Cleaning 5–58. . . . . . . . . . . . . . . . . . . . . . . . . 5.8.4 Cleaning the Hopper, Delivery Cylinder, and S-Tube 5–61. . . . . . 5.8.5 Truck superstructure and Post-Washing Operations 5–64. . . . . .

5.9 Teardown 5–65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9.1 Boom Teardown 5–65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9.2 Outriggers Teardown 5–69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9.3 Controls Teardown 5–70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.10 Pumping Concrete with the Emergency Stroke Kit 5–72. . . . .

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6 Maintenance 6–1. . . . . . . . . . . . . . . . . . . .

6.1 Maintenance Intervals 6–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2 General Tightening Torques 6–4. . . . . . . . . . . . . . . . . . . . . . . . . . 6.2.1 Flared Screwed Joint, Reassembly 6–6. . . . . . . . . . . . . . . . . . . . . 6.2.2 Profiled Ring Joint, Reassembly 6–6. . . . . . . . . . . . . . . . . . . . . . . .

6.3 Functional Fluids 6–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3.1 Hydraulic Fluid 6–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3.2 Oil for the Power Take -Off (PTO), Rotor and

Agitator Gearboxes 6–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3.3 Manual Lubrication 6–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3.4 Centralized Lubrication System 6–8. . . . . . . . . . . . . . . . . . . . . . . . 6.3.5 Truck Engine Oil and Transmission Oil 6–8. . . . . . . . . . . . . . . . . . 6.3.6 Level of Contaminant 6–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3.7 Lubricant Analysis 6–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3.8 Storage of Lubricants 6–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.4 Recommended Lubricants 6–10. . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4.1 Hydraulic Fluids 6–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4.2 Oils and Greases 6–12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.5 Visual Checks 6–15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.6 Changing the Hydraulic Fluid 6–17. . . . . . . . . . . . . . . . . . . . . . . .

6.7 Function Checks 6–23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.8 Performing Maintenance on the Accumulator 6–25. . . . . . . . . 6.8.1 Checking Accumulator Pre-Charge Pressure 6–28. . . . . . . . . . . . 6.8.2 Decreasing Accumulator Pressure 6–29. . . . . . . . . . . . . . . . . . . . . . 6.8.3 Increasing Accumulator Pressure 6–29. . . . . . . . . . . . . . . . . . . . . . . 6.8.4 Replacing Accumulator Bladder 6–30. . . . . . . . . . . . . . . . . . . . . . . .

6.9 Filter Change 6–31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.10 Hoses 6–39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.11 Vacuum Meter 6–43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.12 Change of Delivery Piston with KEP 6–45. . . . . . . . . . . . . . . . . .

6.13 Lubricating the S Transfer Tube 6–55. . . . . . . . . . . . . . . . . . . . . .

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6.14 S transfer tube 6 - 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S transfer tube variants 6 - 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.15 Measuring the Wall Thickness (Machines with S Transfer Tube) 6–81. . . . . . . . . . . . . . . . . . . . . .

6.16 Lubricating the M 36Z Placing Boom 6–87. . . . . . . . . . . . . . . . .

6.17 Lubricating the Boom Pedestal (TRDI 70) 6–89. . . . . . . . . . . . . Lubrication Points with No Central Lubrication Manifold 6–90. . . Lubrication Points with Central Lubrication Manifold 6–90. . . . . .

6.18 Replacing the Delivery Line 6–91. . . . . . . . . . . . . . . . . . . . . . . . . .

7 Troubleshooting Guide 7–1. . . . . . . . . . .

7.1 Concrete Pump 7–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.2 Placing Boom 7–8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3 Boom Control 7–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.4 Electrical System 7–9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A820062_01_0208D 1–1

1 Guide to the Operating Instructions

These Operating Instructions are intended to familiarize the user withthe machine and to assist them in using the machine properly in variousoperations.

The Operating Instructions contain important information on how tooperate the machine safely, properly, and efficiently. Observing theseinstructions helps to avoid danger, to reduce repair costs anddowntimes, and to increase the reliability and service life of themachine.

The Operating Instructions are to be supplemented by the respectivestate, local, and national rules and regulations for accident preventionand environmental protection.

The Operating Instructions must always be available wherever themachine is in use.

These Operating Instructions must be read and applied by any personin charge of carrying out work with and on the machine, such as:• Operation, including setting up, troubleshooting in the course ofwork, or tearing down the machine

• Service (maintenance, inspection, repair)• Transport

In addition to the Operating Instructions and mandatory rules andregulations for accident prevention and environmental protection in thecountry and place of use of the machine, the generally recognized rulesof technology for safe and proper working must also be observed.

1.1 Foreword

Guide to the Operating Instructions

A820062_01_0208D1–2

Should you have any questions following your study of the OperatingInstructions, the Branch or Agency serving you, or PutzmeisterAmerica in Racine, WI will be happy to give you more information.

You will make it much easier for us to answer any questions if you cangive us the details of the machine model and the machine serialnumber.

In the interest of constant improvement, modifications are made fromtime to time and it could be possible that we were unable to take theseinto consideration when these Operating Instructions were printed.

All product descriptions, illustrations and specifications were in effectat the time the manual was released for printing. Putzmeister reservesthe right to make changes in design or to make additions to orimprovements in its products without imposing any obligations uponitself to install them on products previously manufactured.

The contents of this publication may not be reproduced, even inextract, without our written permission. All technical data, drawings,etc. are protected by copyright.

E copyright by


A820062_01_0208D 1–3

The following icons and symbols are used in the OperatingInstructions:

" Task symbolText following this symbol describes tasks which you are required towork through, generally from top to bottom in the sequence shown.

⇒ Text following this symbol describes the result or effect of an action.

Refer also to the maintenance cards:This symbol is used to refer to the maintenance cards required, possi-bly as a supplement to the maintenance card you are currently reading.

The following special tools are required:This icon identifies the special tools necessary to carry out the work.Normal tools (i.e., commercially--available tools or tools carried in thetruck) are not specially listed.

Environmental protectionParticular information regarding environmental protection isintroduced by the icon shown, the words Environmental protectionprinted in bold, and a line. The associated text is printed in italics andends with another line.

NoteParticular information regarding the economic use of the machine isintroduced with the icon illustrated, the word Note printed in bold, anda line. The associated text is printed in italics and ends with anotherline.

CautionParticular information or rules or prohibitions intended to preventdamage are introduced with the icon illustrated, the word Dangerprinted in bold, and a line. The associated text is printed in italics andends with another line.

1.2 Icons and symbols


A820062_01_0208D1–4

DangerParticular information or rules or prohibitions intended to preventinjury or significant damage are introduced with the icon illustrated,the word Danger printed in bold, and a line. The associated text isprinted in italics and ends with another line.

The appropriate symbol will be used if it is possible to identify thesource of the danger precisely.

Danger of fireThis symbol is used to identify tasks for which there is a particular dan-ger of fire.

Danger of explosionThis symbol is used to identify tasks during which there is the danger ofan explosion. The explosion may also be caused by pressure being re-leased suddenly.

Falling itemsThis symbol is used to identify tasks in which there is a danger of injurycaused by parts falling down.

Danger of crushingThis symbol is used to identify tasks during which there is the danger ofbeing crushed.


A820062_01_0208D 1–5

Suspended loadThis symbol is used to identify tasks in which suspended loads may falldown.

High voltageThis symbol is used to identify tasks in which there is the danger ofelectrocution, possibly with lethal consequences.

Danger of burningThis symbol is used to identify tasks in which there is a danger of burn-ing from chemical substances which are not specifically described.

Danger of burningThis symbol is used to identify tasks in which there is a danger of burn-ing from battery acid.

Danger of poisoningThis symbol is used to identify tasks in which there is a danger of poi-soning by inhalation of gases, ingestion of or contact with substances.


A820062_01_0208D1–6

A820062_02_0208D 2–1

2 Safety Regulations

Putzmeister America cannot anticipate every possible circumstancethat might involve a potential hazard. The warnings in this manual aretherefore not all inclusive. If a procedure, tool, device, or work methodnot specifically recommended by Putzmeister is used, you must satisfyyourself that it is safe for you and others. You should also ensure thatthe machine will not be damaged or made unsafe by the proceduresyou choose.

Each truck-mounted concrete pump has undergone a thorough QualityControl inspection at the factory. The design incorporates built-insafety features, however it can be potentially dangerous in the hands ofuntrained or careless operators.

Knowing the characteristics of the machine and function of the controlsis important for safe, proper operation, and use. Becoming familiarwith the controls and practices of concrete pumping will result inefficient and smooth pumping.

This topic: Starts on page:

2.1 Personnel Qualifications 2–2

2.2 Safety Regulations 2–2

Safety Regulations

A820062_02_0208D2–2

Only qualified personnel must be allowed to operate, repair, ortroubleshoot the truck-mounted concrete pump:• A qualified operator is one who has read and understood theinstructions in this manual and is thoroughly familiar with theoperating characteristics and limitations of the machine.

• Qualified operators must:-- Read and have a thorough understanding of all precautions

mentioned in the “Safety Booklet for Concrete PumpOperators (BP1742GB--3)”.

-- Know and follow all decals and operating instructions.-- Understand and obey all applicable Local and Government

statutes and regulations applying to safe operation and use ofconcrete pumping machines.

-- Report any damage, defects, problems, or accidents to theirsupervisor immediately.

• Repair and adjustments must only be made by qualified personnel.• All personnel assigned to repair or troubleshoot the truck-mountedconcrete pump must be thoroughly familiar with and understand thejob they are about to do. If in doubt, use extreme caution and obtainassistance from other trained/qualified personnel. Problems mayarise that seem singular but may be due to several causes.

All personnel operating, assembling, transporting, or maintaining atruck-mounted concrete pump should be aware of and comply with thefollowing safety regulations:• No modification is to be made to the machine without prior writtenconsent of the Putzmeister Technical Support or EngineeringDepartment.

• While operating the unit, wear personal protective equipment (safetygoggles, hard hat etc.) required by Federal, State, local and job siteregulations.

• Do not operate the unit unless it has been leveled and stabilized.• Do not operate a malfunctioning unit.• Keep decals and operating instructions legible and readable.• Make sure safety devices are in good operating condition.• Do not clean, oil, adjust, or service unit while it is operating.• Use extreme caution when handling delivery system. Thetruck-mounted concrete pump is capable of delivering very highpressures. Pressure can remain in the delivery system even after theunit is shut down.

2.1 PersonnelQualifications

2.2 Safety Regulations

Safety Regulations

A820062_02_0208D 2–3

• Never remove the hopper grate cover when the pump is in operation.It protects against accidental contact with the remixer shaft and othermoving parts inside the hopper.

• Never enter the hopper with any part of your body; it is a dangerarea and physical injury can occur, even if the engine is stopped.

• Do not stand on the hopper grate.• If work must be performed inside the hopper, ensure that engine isOFF and accumulator pressure reads zero. The system uses ahydraulic accumulator which contains a stored charge of highpressure oil to shift the S-tube. On all machines, ensure that theaccumulator is depressurized.

• Since hydraulic oil systems can be dangerous, know the circuit youare repairing. It may contain high pressure and injury could occur. Ifin doubt, stop the machine and allow sufficient time for the oilpressure to decrease to zero. Check pressure gauges to confirm thatthey read zero.

• Do not open the concrete delivery system without relieving thepressure. Normally, pressure can be relieved by reversing the pumpand pumping backwards. However, in the event of a rock jam,reversing the pump may not relieve the pressure under allconditions.

• When hydraulic cylinders are used to hold loads, do not loosenfittings without mechanically supporting the load. Loosening offittings may result in high pressure fluid leaks and movement of thecylinder.

• Do not fill the fuel tank while the engine is running or hot. Avoid thepossibility of spilled fuel, which may cause a fire.

• If a fuel spill occurs, do not restart the engine until all spilled fuelhas been cleaned up.

• Do not pour material into hopper without grate in place. Operatormust monitor material being dumped in hopper, watching forunmixed or dry concrete, sticks, pieces of metal and other foreignobjects.

• If machine is to be left unattended on a job site, secure it fromunauthorized use or movement.

• Clear area before activating outriggers.• Ensure that a proper level is maintained in the hydraulic oil tank.Oil level below minimum can cause hydraulic pump and systemdamage.

Safety regulations

2 — 4 BPUS03_004_0010EN

Use other than that above or going beyond such use, such as lifting loads, forinstance, is considered contrary to the designated use. Putzmeister Werkaccepts no liability for damage resulting from such use. The risk of suchmisuse lies entirely with the user.

22000600

The placing boom must never be used for lifting loads.

High--pressure delivery over 1232 psi (85 bar) concrete pressure through theplacing boom delivery line is prohibited. The delivery line and end hose areonly suitable for pressures up to 1232 psi (85 bar) in their new condition.

2.3 Use contrary to thedesignated use

2.3.1 Lifting loads

Safety regulations

2 — 5BPUS03_004_0010EN

Extension of the placing boom and end hose beyond the length specified onthe boom rating plate is forbidden.

42500101

Extending the end hose is not permitted.

End hoses may not be fitted with any extension coupling, spout, “swanneck”, outlet shoes or other dangerous outlet fitting or similar device.

12502000

No coupling, spout, swan neck or similar on the end of the end hose

2.3.2 Extending theend hose

2.3.3 End hose with spout

Safety regulations

2 — 6 BPUS03_004_0010EN

It is prohibited to attach an extension (eg freely suspended crossbeam) to theend hose or boom tip in order to extend the reach or to pump “round thecorner”, so to speak. Since the boom and the lifting equipment for theextension have differing pivotal points and modes of control, it is notpossible to coordinate their movements.

Impermissible extensions always place a load on the boom and result inirreparable damage, as forces which the boom is not designed to withstandare conducted into it. At worst, the boom may break or the machine couldtopple over.

If, for reasons related to the site layout, pumping must be carried out overgreater reaches or in inaccessible places, it must be performed in accordancewith the Operating Instructions and a separate delivery line must be laid.

BPUS03_004_0010EN1

2.3.4 Extending the reach

Safety regulations

2 — 7BPUS03_004_0010EN

BPUS03_004_0010EN2

It is forbidden to stand on the placing boom

DangerA fall from a working height of 3.3 ft (1 m) above the ground presents alethal danger.

It is therefore forbidden to stand on the placing boom, to climb up it, or touse it as a working platform or as an aid to climbing.

Always use specially designed or otherwise safety--oriented ladders andworking platforms when working at height greater than 3.3 ft (1 m) abovethe ground. You must wear a safety harness when working at greater heights.

2.3.5 Standing on theplacing boom

Safety regulations

2 — 8 BPUS03_004_0010EN

We state here expressly that Putzmeister accepts no liability for damagearising from incorrect or negligent operation, servicing or maintenance or asa result of use contrary to the designated use. This statement is equally validfor modifications to, additions to and customization of the machine whichmay compromise safety. The guarantee will no longer be valid in such cases.

Please consult us should you wish to deliver higher density media. It may bethe case that suitable measures, such as reducing the reach, are necessary.

2.3.6 Exclusion of liability

A820062_03_0208D 3–1

3 General Technical Description


3.1 36Z Overview Diagram 3–2

3.2 Technical Data 3–3

3.3 Machine Rating Plate 3–3

3.4 Boom Rating Plate 3–4

3.5 36Z Range Diagram 3–5

3.6 Description of the Functions 3–6

3.7 Symbols for the Control System 3–8

3.8 Electrical Control Devices 3–15

3.9 Hydraulic Control Devices 3–42

3.10 Other Components 3–50

General Technical Description

A820062_03_0208D3–2

3.1 36Z Overview Diagram

1 2 3

4 5

6

7 8 9 1110 12 13 14 15 16 17

36Z Overview Diagram

1 Flushing water pump (on the water tank) (page 3–50)2 End hose (on the boom tip) (page 3–51)3 Boom rating plate (page 3–4)4 Radio (page 3–28) and/or cable control (page 3–26)5 Documentation accompanying the product6 Vibrator (on the hopper grate) (page 3–54)7 Transfer tube (page 3–7)8 Hopper grate cutout device (page 3–39)9 Agitator lever (page 3–45) , and water pump lever (page 3–46)10 Accumulator dump valve (page 3–47) and transfer tube damping cock

(page 3–47)11 Proximity switch junction box (on the compact block) (page 3–36) and

manual volume control (page 3–49)12 Outrigger pads13 Hydraulic fluid radiator (one on each side) (page 3–55)14 Outriggers control block (one on each side) (page 3–43)15 Electric control box (page 3–16)16 Boom control block (behind right front outrigger leg) (page 3–44)17 Machine rating plate (page 3–3)


A820062_03_0208D 3–3

The technical data and settings for your machine are located on themachine card and the pump and boom test reading sheets with the mostimportant data also provided on data plates attached to the machine andboom.

The following rating plate is attached to the machine:

Sturtevant, WI 53177Racine Operation 1733 90th Street

-- INC.

A800055 Rev.B

Made in USA

1

2

3

4

5

6

7

8

Machine Rating Plate

1 Model (machine model)2 Serial No. (machine serial number)3 Model year4 Hydr. press max. [bar] (maximum fluid pressure in the hydraulic system)5 Gear/Max. RPM (maximum engine speed for pumping concrete)6 GVW rating [lbs] (permitted gross weight)7 Concrete press. [bar] (maximum delivery pressure)8 Gear/Max. RPM (maximum engine speed for pumping concrete)

3.2 Technical Data

3.3 Machine Rating Plate


A820062_03_0208D3–4

The following plate is attached to the boom:

Putzmeister Inc.

Racine Operation

m

m

m

bar

PN A800002 Rev. 1

Lb/Cu.ft

1733 90th StreetSturtevant, WI 53177

4

5

6

7

8

1

2

3

12

bar9

Lb/ft11

Lb/ft13

mm10

Boom Rating Plate

1 Boom model2 Boom serial no. (machine number)3 PN of arm assembly (arm assembly part number)4 Model year (year of manufacture)5 Horizontal reach max. (maximum horizontal reach)6 Vertical reach max. (maximum vertical reach)7 End hose length max. (maximum end hose length)8 Max. hydr. pressure (maximum hydraulic fluid pressure)9 Max. concrete pressure in delivery line10 Pipe (maximum permitted pipe diameter and wall thickness of the delivery

line) [mm]11 Max. wt. of boom pipeline WITHOUT CONCRETE12 Max. allowable bulk density of concrete to be pumped13 Max. wt. of boom pipeline INCLUDING CONCRETE

3.4 Boom Rating Plate


A820062_03_0208D 3–5

3.5 36Z Range Diagram

END HOSE NOT TO BEOPERATED IN CAUTION AREA

20m

30m

40m

10m

10m

20m

65’7”

32’10”

32’10”

65’7”

98’5”

131’3”

0

32’10”30m 20m 10m 0 10m

32’10”65’7”98’5”

Horizontal Reach 104’

Net Reach 96’2”

Reach

Depth77’9”

Unfolding

Height28’7”

VerticalReach

116’9”

25’4” 25’3”24’9”28’8”

365°

100°

246°

180°

180°

116’9”

77’9”

104’

234°

20’8”

23’

3°

36Z Range Diagram


A820062_03_0208D3–6

This section is intended to help you understand the functions of themachine so that you can restrict the field of the machine’s applicationsto suitable areas and avoid errors in operation.

The boom arms are of box construction. They are actuatedhydraulically. Arm hinges with excellent angular range, incombination with the powerful slewing gear with its wide slewingrange, provide very flexible movement.

The delivery and riser lines comprise standard straight pipe sectionsand elbows. These are thus easily replaced. Clamp couplings serve asboth pivot joints and pipe connectors. The elbow pivot at the end of theboom acts as a brake on the falling concrete and reduces the wear on theend hose.

The telescopic-style front outriggers and swing-out rear outriggers,which provide the required stability, are fitted with fully hydraulicsupport cylinders.

All boom movements are effected hydraulically. All boom cylindershave two integral safety valves to provide protection againstoverloading or rupture of the hydraulic lines. The hydraulic fluidsupply is sufficient to operate a number of cylinders simultaneously.The hydraulic control can be operated from the concrete pump or byusing a portable remote control unit.

The control valves are actuated:-- electrically; or-- electro--hydraulically.

The hydraulic fluid tank is integrated in the boom pedestal.Compressed air and control current are taken from the truck.

3.6 Description ofthe Functions

3.6.1 Boom

3.6.2 Delivery Line

3.6.3 Outriggers

3.6.4 Hydraulic Control


A820062_03_0208D 3–7

PM concrete pumps are driven hydraulically by diesel engine poweredfluid pumps. The delivery pistons (4) are hydraulically linked togetherthrough the driving cylinders (5). They operate in a push--pull mode.The returning delivery piston sucks the concrete in. At the same time,the advancing delivery piston forces the concrete sucked in previouslyinto the delivery line through the pressure pipe or the pressure elbow(1). The pump switches over at the end of the stroke. The transfer tube(2) swings over to the full delivery cylinder (3) and the delivery pistons(4) reverse their direction of movement.

Reverse strokeReversal of the delivery pistons’ (4) movement in the middle of thestroke movement. The transfer tube (2) does not switch. The concreteis sucked back from the delivery line into the hopper.

SwitchoverReversal of the delivery pistons’ (4) direction in the middle of thestroke movement. The transfer tube (2) switches over. The concrete isstill pumped without interruption. Switching over helps prevent theformation of blockages.

12

3

4

5

1 Pressure elbow2 Transfer tube3 Delivery cylinder4 Delivery piston5 Drive cylinder

3.6.5 Concrete Pump

3.6.6 S Transfer Tube


A820062_03_0208D3–8

This section gives you a summary of the symbols used for controlactions.

3.7.1 Concrete Pump (Part 1)

20007601

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15

No 0 Designation

1 Pump in general2 Rotor pump in general3 Pump stand by

4 Pump On/Off5 Pump on6 Pump off

7 Reverse pumping8 Stroke change--over9 Increase -- reduce pumping rate (using rotary controller)

10 Increase -- reduce pumping rate (using toggle switch)11 Increase output

12 Reduce output13 Hare = fast14 Snail = slow

15 Cleaning

3.7 Symbols for theControl System


A820062_03_0208D 3–9

3.7.2 Concrete Pump (Part 2)

20007602

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16

17

No 0 Designation

1 Agitator in general

2 Agitator clockwise rotation3 Agitator counterclockwise rotation4 Agitator safety cutout

5 Level control6 Hopper full7 Hopper empty

8 Water tank heating9 Mixer in general10 Mixer mix or fill

11 Mixer drain12 Vibrator in general

13 Vibrator On14 Vibrator Off15 Water pump auxiliary unit

16 Water pump17 Compressor


A820062_03_0208D3–10

3.7.3 Engine

20007603

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16

17 18 19

No 0 Designation

1 Truck in general2 Power take--off3 Ignition monitoring4 Diesel engine on5 Diesel engine off6 Charge monitor7 Engine oil pressure8 Silent (low noise)9 Engine speed in general10 Engine speed11 Increase engine speed12 Reduce engine speed13 Tank monitoring14 ECO (reduced fuel consumption)15 Engine oil temperature16 Coolant temperature17 Coolant level18 Engine fault (V--belt failure)19 Air filter


A820062_03_0208D 3–11

3.7.4 Electrical System (Part 1)

20007604

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16

No 0 Designation

1 Electrical system power2 Electrical system Auto--Manual

3 On -- Off4 On5 OFF

6 Activate EMERGENCY SHUT--DOWN7 EMERGENCY SHUT--DOWN activated8 Operating hours meter

9 Operating position (local control)10 Remote control in general

11 Radio remote control system12 Plug in remote control13 Cable drum

14 Fault in general15 Acknowledge fault16 Battery


A820062_03_0208D3–12

3.7.5 Electrical System (Part 2)

20007605

1 2 3 4 5 6 7 8

9 10 11

No 0 Designation

1 Horn2 Lighting in general

3 Working light4 All--round flashing warning light5 Analogue adjustment

6 Level control7 Electric motor8 Timer relay

9 Fuse10 Fuse test

11 Test operation


A820062_03_0208D 3–13

1 2 3 4 5

No 0 Designation

1 Hydraulic fluid temperature2 Cooling fan

3 Close isolating gate valve (closed)4 Open isolating gate valve (opened)5 Excess pressure

20007607

1 2 3 4 5

6 7

No 0 Designation

1 Support leg function2 Swing out support leg

3 Swing in support leg4 Extend support leg5 Retract support leg

6 Extend support foot7 Retract support foot

3.7.6 Hydraulic System

3.7.7 Outriggers


A820062_03_0208D3–14

3.7.8 Boom

20007609

1

9

2

10

3

11

4

12

5

13

6

14

7

15

8

16

No 0 Designation

1 Boom in general2 Boom functions activated

3 Slewing gear activated4 Slew boom to the right5 Slew boom to the left

6 Move boom7 Do not move boom8 Arm 1 up

9 Arm 1 down10 Arm 2 up

11 Arm 2 down12 Arm 3 up13 Arm 3 down

14 Arm 4 up15 Arm 4 down16 Switch off arm up function


A820062_03_0208D 3–15

The electrical control devices and operating elements on this machineare described on the following pages. The summary at the start of thischapter will show you where the various control devices are located onthe machine. The symbols used on the electrical control devices aredescribed in one of the preceding sections.

The electrical control devices may include the following components,depending on the equipment on your machine.-- Electric control box-- Cable remote control-- Radio remote control system-- Junction box for proximity switches

3.8 Electrical ControlDevices


A820062_03_0208D3–16

The central module control cabinet is illustrated below. Some of thecontrol and operating elements illustrated below may not be present onyour machine. The hole will be covered with a blanking plug if acontrol or operating element is omitted.

You will find the description of any additional door modules and theircontrol and operating elements fitted in place of the blanking plates onthe following pages.

A820062_03_0208D3

1

6

10

11 11

11 11

12

2

543

7 8 9

No 0Operating/control element

Meaning/FunctionBelongswith no:

1 Red indicator lamp (optional) Coolant overheating 42 Red indicator lamp (optional) High--pressure water pump

dry--running cut--out3 Toggle switch Hydraulic fluid radiator On -- Off

4 Toggle switch (optional) Coolant overheating Off 15 Toggle switch (optional) Pumping operation -- Service operation

6 Toggle switch (optional) Working light On -- Off

3.8.1 Central ModuleControl Cabinet


A820062_03_0208D 3–17

A820062_03_0208D4

1

6

10

11 11

11 11

12

2

543

7 8 9

Continued

NoOperating/control element


7 Toggle switch (optional) Working light On -- Off8 Toggle switch (optional) Working light On -- Off9 Locally latched toggle switch Local control -- 0 -- Remote control10 Multiple display Display11 Blanking plate Options for door modules12 Female connector Connection for remote control


A820062_03_0208D3–18

A820062_03_0208D5

1 2

3 4 6 75

No 0 Control element Meaning/FunctionBelongswith no:

1 Thermometer Hydraulic fluid temperature display

2 Operating hours meter Operating hours display3 Green display Forward pumping On4 Green display Reverse pumping On

5 Red display Hydraulic fluid overheating /Temperature sensor lead break

6 Red display EMERGENCY SHUT--DOWN activated7 Green display Hydraulic fluid radiator fan On

Multiple Display


A820062_03_0208D 3–19

Special Features of the Control Cabinet

To use a toggle switch that has been latched locally, you must first pullit out and then push it towards the symbol.

The control cabinet may be found in a stowage compartment. You mustalways lock this stowage compartment to prevent any unauthorizedperson switching the control system over.

The EMERGENCY SHUT--DOWN circuit is activated automaticallywhen you switch over from local to remote control. You must operatethe horn to deactivate the EMERGENCY SHUT--DOWN circuit.

The “Coolant overheating” indicator lamp is connected to the vehicle’swarning system. In the event of an engine fault, the machine isswitched to EMERGENCY SHUT--DOWN and the engine is shutdown. Once you have eliminated the fault, you must press the “Coolantoverheating Off” toggle switch before you can restart the engine. Youcan override the shut--down by holding down the “Coolant overheatingOff” toggle switch in order to operate the machine for a short time (egto pump out the hopper and delivery line).

Use the “Pumping operation -- Service operation” toggle switch toswitch over between the concrete pump and the compressor. You canswitch on the compressor, rather than the pump, at the remote control ifyou set the switch to “Compressor”.

NoteAs soon as the compressor is switched on, the agitator control block isno longer supplied with hydraulic fluid, ie the agitator and the waterpump will not run.

Locally latchedtoggle switches

Locking

Switchover from local toremote control

Coolant overheating

Pumping operation -- Ser-vice operation


A820062_03_0208D3–20

The hydraulic fluid temperature is measured at the main hydraulicpump. The left--hand green LED flashes if the hydraulic fluid tempera-ture is below approximately 65 _C at this point.The left--hand LED of the two red LEDs lights up if the hydraulic fluidtemperature exceeds 90 _C. The red “Hydraulic fluid overheating” dis-play lights up at the same time. The two red LEDs flash alternately ifthe hydraulic fluid temperature exceeds approximately 95 _C.

The operating hours meter is activated when the pump is switched on.The flashing egg--timer symbol in the display indicates that the meter isactive.

These displays indicate the machine’s statuses. The two red displaysindicate the following:-- “EMERGENCY SHUT--DOWN activated” symbol lights up:EMERGENCY SHUT--DOWN activated

-- “Hydraulic fluid overheating” symbol lights up: The hydraulic fluidis too hot. The red LEDs in the temperature display light up or flashdepending on the temperature.

-- “Hydraulic fluid overheating” symbol flashing: The temperaturesensor on the main hydraulic pump is defective or there is a break inthe cable. The two red LEDs in the temperature display flash alter-nately and the hydraulic fluid radiator fan begins to run at the sametime (one fan runs where there are two hydraulic fluid radiators).

CautionIn the event of a fault or a line break to the temperature sensor on themain hydraulic pump, the switch--off temperature (90 _C) for the hy-draulic fluid is no longer monitored. This means that the machine willnot be switched off should the hydraulic fluid overheat.

Switch the machine off and replace the temperature sensor if the “Hy-draulic fluid overheating” display flashes.

Hydraulic fluid tempera-ture display in the mul-tiple display

Operating hours display inthe multiple display

Status displays in the mul-tiple display


A820062_03_0208D 3–21

The control panel is located in or near the steps. The truck mixer drivercan control the most important functions of the pump from the controlpanel. In addition, it provides an opportunity for local operation of themachine. Some of the control and operating elements illustrated belowmay not be present on your machine. The hole will be covered with ablanking plug if a control or operating element is omitted.

A820062_03_0208D6

8

7

6

5

4

1

2

3



1 Green indicator lamp Boom centralized lubrication system2 Toggle switch Increase -- Reduce engine speed

3 Toggle switch Vibrator On -- Off4 Momentary--contact switch EMERGENCY SHUT--DOWN5 Toggle switch Horn + deactivate EMERGENCY SHUT--

DOWN / Pump Off6 Toggle switch Forward pumping -- 0 -- Reverse pumping7 Toggle switch Centralized lubrication system8 Green indicator lamp Pump centralized lubrication system

3.8.2 Control Panelin the Steps


A820062_03_0208D3–22

Special Features of the Control Panel

If you have pressed the EMERGENCY SHUT--DOWN button, youmay only start the pump up again as described below:-- unlock the EMERGENCY SHUT--DOWN button by turning it,-- press the “Horn + deactivate EMERGENCY SHUT--DOWN” toggleswitch,

-- switch the pump off and then on again using the “Forward pumping--0 -- Reverse pumping” toggle switch.


The function of the “Forward pumping -- 0 -- Reverse pumping” toggleswitch depends on the switch position of the Local--Remote switch onthe control cabinet.-- When the toggle switch is set to “Local”, it has the functions givenabove.

-- When the switch is set to “Remote”, it is only possible to switch thepump off using the “Pump off” toggle switch.

The centralized lubrication system for this machine is described on thefollowing pages.

NoteIf your machine is equipped with pump centralized lubrication system,the pump centralized lubrication system and the boom centralized lu-brication system are two completely independent systems, that is twopumps, two lubricant reservoirs, two controllers, etc. The toggle switchcan then be pressed in either direction and it will address the systemselected.

Restart pump afterEMERGENCYSHUT--DOWN


Forward pumping -- 0 --Reverse pumping

Centralized lubricationsystem


A820062_03_0208D 3–23

Technical data Rated voltage (V DC) 12 / 24

Operating voltage (V DC) 10 ... 30

Off--load current at 12 V (mA) 15

Off--load current at 24 V (mA) 18

Motor current (A) 6

Lamp current (A) 2

Ambient temperature (˚C) --40 ... +80

Inputs secure against polarity reversal

Outputs secure against polarity reversal/short--circuit protected

Relative operating period (%) 100

Degree of protection fitted in thepump casing IP 6 K 9 K DIN 40050 T9


A820062_03_0208D3–24

The indicator lamps give you information regarding the function of thecentralized lubrication system or of any faults on it.

NoteWhen the pump is switched on, the indicator lamp lights up forapproximately 2 seconds and the system is tested. The lubricating mo-tors will run for a fraction of a second. The indicator lamps will go outafter 2 seconds if the system is in order. A flashing indicator lamp indi-cates one of the conditions described below.

Flash interval Meaning

2 seconds on, then off Self--test after pump switched on

1 second on, 1 second off Fault in the drive motor or supply line

½ second on, ½ second off Lubricant reservoir empty

½ second on, 1 second off Fault in the lubrication circuit

Lubrication in progress

Steady light A fault which was previously indicated has beenacknowledged (see “toggle switch”)

Indicator lamps


A820062_03_0208D 3–25

Various settings are programmed into the centralized lubrication sys-tem in the works. These settings regulate the lubrication intervals andthe lubrication time. Have the default settings modified by the AfterSales Department if either the lubrication intervals or the lubricationtimes do not meet your needs. The following settings are stored:

The interval time is the time between two lubrication procedures.The interval time only runs down when the ignition is switched on. Theinterval times are retained during interruptions. The new times areadded on restarting.

The working time is the time for which the centralized lubricationpump operates for one lubrication procedure. The working time is theperiod during which a response must be received from the piston de-tectors.

The monitoring time starts when the centralized lubrication pumpis switched on. The monitoring time is the time taken for the pistondetector to respond.

Programming

Interval time

Working time

Monitoring time


A820062_03_0208D3–26

The standard cable remote control for this machine is illustrated below.

A820062_03_0208D7

2

3

6

7

9

11

1

1

5

48

10



1 Joystick Boom control2 Rotary controller Setting the boom speed if no 6 is switched to

the “Snail” switch position6

3 Toggle switch Forward pumping -- 0 -- Reverse pumping

4 Toggle switch Horn + deactivate EMERGENCY SHUT--DOWN /Change--over

5 Rotary controller Increase -- Reduce output

6 Toggle switch Boom speed preselection:Hare = 100%Snail = 0 -- 100%

2

7 Toggle switch Engine On -- Off8 Toggle switch Increase -- Reduce engine speed

9 Locally latched toggleswitch

Boom functions -- 0 --Support leg control

10 Red indicator lamp Fault (eg EMERGENCY SHUT--DOWNoperated)

11 Momentary--contact switch EMERGENCY SHUT--DOWN

3.8.3 Cable RemoteControl


A820062_03_0208D 3–27

Special features of the cable remote control

The red “Fault” indicator lamp lights up when the EMERGENCYSHUT--DOWN button is pressed. You may only start the pump upagain as described below:-- unlock the EMERGENCY SHUT--DOWN button by turning it,-- press the “Horn + deactivate EMERGENCY SHUT--DOWN” toggleswitch,

-- switch the pump off and then on again using the “Forwardpumping -- 0 -- Reverse pumping” toggle switch.


Restart pump afterEMERGENCYSHUT--DOWN



A820062_03_0208D3–28

The transmitter for a proportional radio remote control is describedbelow.

A820062_03_0208D8

1

2

3

4

5

6

7

8

9

10

11

12 13



1 Joystick Boom control2 Toggle switch Radio remote control unit On -- Off 12

3 Toggle switch Forward pumping -- 0 -- Reverse pumping4 Toggle switch Horn + deactivate EMERGENCY SHUT--

DOWN / Change--over5 Rotary controller Increase -- Reduce output

6 Locally latched toggle switch Preselect boom speed:Snail = 50% of the works setting --User--defined speed --Hare = 100% of the works setting

10

3.8.4 Radio RemoteControl


A820062_03_0208D 3–29

A820062_03_0208D9

1

2

3

4

5

6

7

8

9

10

11

12 13

Continued

NoOperating/control element


7 Toggle switch Engine On -- Off8 Toggle switch Increase -- Reduce engine speed9 Locally latched toggle switch Boom functions -- 0 -- Support leg control

10 Toggle switch Program user--defined boom speed 711 Momentary--contact switch STOP function12 Green indicator lamp Flashing: remote control unit in service

Off: no contact with receiver2

13 Red indicator lamp Flashing: battery flat


A820062_03_0208D3–30

A820062_03_0208D10

1

2

4

5

6

3



1 Female connector Antenna connection

2 Antenna with base Control signal reception3 Battery compartment Charge battery4 Indicator lamps Operating states display

5 Red indicator lamp Battery charge state6 Female connector Connection to the control cabinet

Receiver


A820062_03_0208D 3–31

Special features of the radio remote control

Putzmeister radio remote controls include a STOP button having thesame function as the EMERGENCY SHUT--DOWN buttons on themachine. This is a requirement of European standard EN 60204--1.

You may only start the pump up again as described below if you havepressed the STOP button:-- unlock the STOP button by turning it,-- switch remote control unit off and back on again,-- press the “Horn + deactivate EMERGENCY SHUT--DOWN”toggle switch,

-- switch the pump off and then on again using the “Forward pumping-- 0 -- Reverse pumping” toggle switch.

12 frequencies on the frequency band have been assigned to this radioremote control. As soon as you switch the transmitter off or press theSTOP button on the transmitter, the link between the transmitter andreceiver is broken. The radio remote control automatically advances tothe next frequency when you switch the transmitter back on.

You must maintain a minimum clearance of 1 m between the radio re-mote control antenna and any additional antennae (eg radio, telephone)you fit, as otherwise these may interfere with the radio remote control.


The two joysticks can be used to control the individual boom functions.You can control some of the boom functions for 4 and 5 arm booms byrotating the joysticks.

STOP button

Restart pump after STOP

Frequency change

Additional antennae


Joystick


A820062_03_0208D3–32

You can select different speeds of movement for the boom using the“Preselect boom speed” toggle switch.-- In the Snail position of the switch, the boom functions are operatedat 50% of the speed set in the works.

-- In the middle position of the switch, the boom functions are operatedat the user--defined speeds of movement.

-- In the Hare position of the switch, the boom functions are operatedat 100% of the speed set in the works.

You can program your own speed for each of the boom functions usingthe “Program user--defined boom speed” toggle switch.-- You program the maximum boom speeds with the toggle switchin the upper position.

-- You program the minimum boom speeds with the toggle switchin the lower position.

Each boom movement must be programmed individually.

Programming a maximum speed

" Set the “Preselect boom speed” toggle switch to “User--definedspeed”.

" Press the “Program user--defined boom speed” toggle switch upand hold.

" Use the joystick to control the boom movement desired at thespeed that is to become the maximum speed for full joystickdeflection.

" Release the toggle switch first and then the joystick.

Preselect boom speedtoggle switch

Program user--definedboom speed toggle switch

Programming your ownboom speed


A820062_03_0208D 3–33

Programming a minimum speed

" Set the “Preselect boom speed” toggle switch to “User--definedspeed”.

" Press the “Program user--defined boom speed” toggle switchdown and hold.

" Use the joystick to control the boom movement desired at thespeed that is to become the minimum speed for minimum joys-tick deflection.

" Release the toggle switch first and then the joystick.

Now when you set the “Preselect boom speed” toggle switch to themiddle position and move the joystick to its full deflection, the boommovement will be executed at the maximum speed of movement youhave just programmed. When you now move the joystick only slightly,the boom movement will be executed at the minimum speed of move-ment you have just programmed.

NoteThe electronics in the radio remote control prevent you programming aminimum speed that is higher than the maximum speed.

If you move the joystick only very slightly so that the boom does notmove when you are programming the maximum speed for a boommovement, this direction of movement will be inhibited.

Inhibiting individual armmovements


A820062_03_0208D3–34

There are a number of EMERGENCY SHUT--DOWN buttons on themachine. These are located:-- by every outrigger control block-- on the cable and radio remote control boxes-- on the electric control box or near the hopper

Some possible positions of the EMERGENCY SHUT--DOWN buttonare shown in the illustration below.

CautionFamiliarize yourself with the locations of the EMERGENCYSHUT--DOWN buttons on your machine before operating the unit.

30505901

EMERGENCY SHUT--DOWN button

NoteYou need only press one of the EMERGENCY SHUT--DOWN buttons totrigger an EMERGENCY SHUT--DOWN of the machine.

To release the EMERGENCY SHUT--DOWN condition again, you mustunlock the EMERGENCY SHUT--DOWN button that has been pressedby turning it and sound the horn.

You must switch the pump off and back on again to restart the pump.All EMERGENCY SHUT-DOWN buttons must be released for machineoperation.

3.8.5 EMERGENCYSHUT-DOWN Button


A820062_03_0208D 3–35

The following actions are triggered in the truck, pump and boom systems when you press one of theEMERGENCY SHUT--DOWN buttons:

System Action

Truck -- Engine speed drops to idle.-- It is no longer possible to set the engine speed electrically.

Pump -- The “EMERGENCY SHUT--DOWN operated” indicator lamp lights on the controlcabinet.

-- Variable main pumps go to neutral, the delivery pistons come to a halt, and the “PumpOn” light flashes.

-- The change--over valve is de-energized.

DangerThe accumulator pump continues to generate hydraulic flow, which is directed back totank instead of operating the function (i.e., the accumulator ceases to be filled).

Boom -- The boom control unit is disconnected.-- If the E-stop on the radio transmitter was pressed, the supply voltage to the radiotransmitter is switched off and the power indicator lamp on the radio transmitter goesout. If an E-stop on the truck was pressed, the power indicator lamp on the radiotransmitter flashes.

-- On the cable remote control system, the supply voltage is switched off with theexception of that for the horn, the “Fault” indicator lamp on the cable remote controlunit lights, the “Pump on” light flashes.

-- The boom pump transports hydraulic fluid in depressurized circulation(maximum 15 bar) through the boom control unit inlet module to the tank. Emergencyoperation of the boom functions is ensured by simultaneous manual operation of theoperating mode selector valve and the corresponding boom arm valve.

DangerThe machine is only switched off electrically when the EMERGENCYSHUT--DOWN button is pressed. Although this causes all theelectrically actuated hydraulic valves to be switched off, anuncontrolled sinking of the boom caused by leakages in the hydraulicsystem, for instance, cannot be prevented in this way.


A820062_03_0208D3–36

The junction box for the proximity switches is located next to thecompact block on the right side (seen in the direction of travel) of thetruck.

20500404

Assignment of Proximity Switches to LEDs

There are four proximity switches located on the right drive cylinder ofthe core pump, two at the front and two at the rear. These switchestrigger the switchover procedure when the hydraulic pistons approachthe proximity switches. The LEDs for the two proximity switches thathave just been triggered light up on the junction box at the same time.

LED Proximity Switch

1 rear (rod side) left

2 rear (rod side) right

3 forward (base side) left

4 forward (base side) right

3.8.6 Proximity SwitchJunction Box

Junction Box LEDs


A820062_03_0208D 3–37

Junction Box LED Proximity Switch Status

Lights up briefly on switchover Proximity switch is in order

Does not light up on switchover Proximity switch, connector orlead are defective, replace at theearliest opportunity

Lights up continuously Proximity switch, connector orlead are defective, disconnect theswitch (otherwise switchover isnot possible) and replace atearliest opportunity

NoteFurther LEDs are located on the Proximity switch connector (see page3–38). These LEDs indicate whether it is the Proximity switch or theconnector and lead that is defective.

One of the two proximity switches on each end is sufficient to triggerthe switchover procedure. The second proximity switch serves as abackup in case one of the two proximity switches should fail. You mayuse one of the proximity switches from the other end as a replacementif both the switches on one end (rod end or base end) fail during a job.

Significance ofthe Junction Box LEDs

Redundant system


A820062_03_0208D3–38

The connector for the proximity switch has one yellow and one greenlight--emitting diode (LED). These LEDs indicate the status of theconnector and the proximity switch.

3

4

1 2

Proximity Switch Connector

1 Yellow LED -- Indicates the status of the proximity switch.2 Green LED -- Indicates the status of the connector and the lead.3 Connector4 Proximity Switch

Yellow LED Proximity Switch Status

Lights up briefly on switchover Proximity switch is in order

Does not light up on switch-over

Proximity switch is defective, replace atearliest opportunity

Lights up continuously Proximity switch is defective, disconnect theswitch (otherwise switchover is not possible)and replace at earliest opportunity

Green LED Connector and Lead Status

Lights up A voltage is being applied to the connector(i.e., connector and lead are in order)

Does not light up No voltage is being applied to the connector(i.e., connector or lead are defective)

3.8.7 Proximity SwitchConnector

Significance ofthe Proximity SwitchLEDs


A820062_03_0208D 3–39

The hopper grate cutout device consists of a switching cam and apressure roller switch. The switching cam is fastened to the hinge pinof the hopper grate, the pressure roller switch to the hopper. Thepressure roller switch is acted on as soon as you open the hopper grate.This causes the agitator to halt and the pressure to be dumped from theaccumulator (i.e. the transfer tube will no longer be able to switchover). In addition, the delivery pistons return to the end position andthe concrete pump halts. You must switch the concrete pump off andback on again to re--start it.

1 2 3 4

Hopper Grate Cutout Device

1 Hopper2 Hopper grate hinge pin3 Switching cam4 Pressure roller switch

DangerThe pressure roller switch must always be clean and free to move. Inaddition, the pressure roller switch must always be in contact with theswitching cam. If the pressure roller switch is defective, the hoppergrate cutout device may not function, or the agitator and the transfertube may come to a halt during pumping operations.

3.8.8 Hopper Grate CutoutDevice


A820062_03_0208D3–40

WarningBEFORE LIFTING HOPPER GRATE TO WORK ON CONCRETE PUMP, VERIFY THATHOPPER GRATE CUTOUT DEVICE IS WORKING PROPERLY BY PERFORMING THEFOLLOWING STEPS: (1) While concrete pump is ON, reach hand beneath cutout cover andpush switch up (refer to diagram below). DO NOT ATTEMPT TO RAISE HOPPER GRATE.(2) Verify that concrete pump turns OFF.

Position of hopper grate cutoutswitch with hopper grateCLOSED. In this position, theconcrete pump can be turned ON.

Hopper grate cutout cover,which is located onpassenger’s side of truck.

Position of hopper grate cutout switchwhen hopper grate is OPEN. In thisposition, the concrete pump shouldautomatically turn OFF.


A820062_03_0208D 3–41

The agitator shut--off valve is incorporated into the agitator controlblock. If there is no power to the agitator shut--off valve (when thehopper is open or the EMERGENCY SHUT--DOWN button has beenpressed), hydraulic fluid does not flow to the agitator valve (i.e., theagitator halts).

1

Agitator Control Valve

1 Agitator shut-off valve

3.8.9 Agitator Shut-OffValve


A820062_03_0208D3–42

The hydraulic control devices and operating elements on this machineare described on the following pages. The summary at the start of thischapter will show you where the various control devices are located onthe machine. The symbols used on the hydraulic control devices aredescribed in one of the preceding sections.

The hydraulic control devices may include the following components,depending on the equipment on your machine.-- Outriggers control block-- Boom functions control block-- Emergency hydraulic ports-- Agitator lever-- Water pump lever-- Compact block valves (e.g., manual volume control valve,accumulator dump valve, etc.)

-- Transfer tube damping cock

NoteFurther control devices and components are described in the“Electrical Control Devices” section on page 3–15 and the“Other Components” section on page 3–50.

3.9 Hydraulic ControlDevices


A820062_03_0208D 3–43

The outriggers control block on the left--hand side of the truck (driver’sside) is illustrated below. The outriggers control block on theright--hand side of the truck (passenger side) is a mirror image of thisone.

22104901

1

2 3 4 5

6

Outriggers Control Block (Located on Driver’s Side)

1 Left outrigger on/off lever -- Push lever in and hold to activate the leftoutrigger controls or release lever to deactivate the left outrigger controls.

2 Outrigger left front (LF) up/down -- Pull lever out to raise LF outrigger orpush in to lower LF outrigger.

3 Outrigger left rear (LR) up/down -- Pull lever out to raise LR outrigger orpush in to lower LR outrigger.

4 Outrigger left front (LF) out/in -- Pull lever out to extend LF outrigger orpush in to retract LF outrigger.

5 Outrigger left rear (LR) out/in -- Pull lever out to extend LR outrigger orpush in to retract LR outrigger.

6 EMERGENCY SHUT-DOWN button

NoteThe support control block is designed as a two--hand control device(i.e. to execute a function, you must operate the on/off lever and thecorresponding function lever simultaneously).

The hydraulic outrigger valves are spring--loaded (i.e., the valves areautomatically reset to the “0” position when you release the lever).

3.9.1 Outriggers ControlBlock


A820062_03_0208D3–44

The control block can be operated manually and thus provides securityof operation if a functional fault occurs in the remote control system.

1 2 3 4 5 6

Boom Functions Control Block (Located on Passenger’s Side of Truck)

1 “D” Arm -- Pull out to raise “D” arm or push in to lower “D” arm.2 “C” Arm -- Pull out to raise “C” arm or push in to lower “C” arm.3 “B” Arm -- Pull out to raise “B” arm or push in to lower “B” arm.4 “A” Arm -- Pull out to raise “A” arm or push in to lower “A” arm.5 Slew -- Pull lever out to slew boom clockwise or push in to slew boom

counter-clockwise.6 Operating mode selector valve (OMV) -- Push to engage boom functions or

pull to engage outriggers.

3.9.2 Boom FunctionsControl Block


A820062_03_0208D 3–45

The agitator control block with the agitator lever is mounted on theright front corner of the hopper. Use the agitator lever to switch on theagitator in either direction of rotation.

1

3

2

4

Operation of Agitator Lever

1 Agitator ON (lever upwards) -- Agitator direction away from the deliverycylinder

2 Agitator OFF3 Agitator ON (lever downwards) -- Agitator direction towards the delivery

cylinder4 Water lever

NoteAs the two valves on the agitator control block are supplied by a singlehydraulic pump, it may be the case that the volume of hydraulic fluid isnot adequate to supply the functions of both valves with sufficienthydraulic fluid at the same time. It can therefore be the case that theagitator does not operate when the water pump is switched on, or thatthe water pump does not operate when the agitator is switched on.

3.9.3 Agitator Lever


A820062_03_0208D3–46

The water pump lever is located next to the agitator lever on theagitator control block.

1

2

3

Operation of Water pump lever

1 Water pump ON2 Water pump OFF3 Agitator lever

NoteAs the two valves on the agitator control block are supplied by a singlehydraulic pump, it may be the case that the volume of hydraulic fluid isnot adequate to supply the functions of both valves with sufficienthydraulic fluid at the same time. It can therefore be the case that theagitator does not operate when the water pump is switched on, or thatthe water pump does not operate when the agitator is switched on.

3.9.4 Water Pump Lever


A820062_03_0208D 3–47

This machine is fitted with an electrical agitator safety cutout. Theaccumulator pressure is dumped through an accumulator dump valveand the transfer tube halts, among other measures, as soon as the grillon the hopper is opened. The accumulator dump valve is located on theleft of the hydraulic block, seen in the direction of travel.

The machine is fitted with an additional accumulator dump cock. Theaccumulator pressure is also dumped when the accumulator dump cockis opened. The transfer tube will still switch over while the machine isrunning, although at a lower pressure and very slowly. This will allowyou to halt the transfer tube in the center position by switching off themachine at the appropriate moment. You can then check the wear ringusing a mirror, for example.

The transfer tube damping cock is incorporated in the hydraulic fluidsupply line to the accumulator.

DangerThe transfer tube will continue to switch over when the accumulatordump cock has been opened and the machine is running. There is still adanger of crushing and severing of limbs.

Never reach into the hopper from below through the wash--out port norfrom above through the grill while the machine is running. Never pokeanything into the hopper.

3.9.5 Accumulator DumpValve, AccumulatorDump Cock, TransferTube Damping Cock


A820062_03_0208D3–48

5

4

1

A820062_03_0208D11

3

2

No 0 Designation

1 Accumulator

2 Additional accumulator dump cock3 Accumulator pressure gauge4 Accumulator dump valve

5 Transfer tube damping cock


A820062_03_0208D 3–49

On this machine, the output is adjusted by means of a proportionalvalve. This proportional valve is integrated in the Free--FlowHydraulics control block. The handwheel required for emergencyoperation is located on the forward end of the Free--Flow Hydraulicscontrol block on the right viewed in the direction of travel.

1

No 0 Designation

1 Emergency operation handwheel

NoteThe proportional valve must be fully open during normal operation,i.e. the emergency operation handwheel must be turned fullycounterclockwise (opened).

A fixed value of 75% is set on the proportional valve when you switchover from remote control to local control on the control cabinet, andthe output can only be controlled by the engine speed. This meansthat an output of 75% of the maximum output is possible at maximumengine speed.

In emergency operation you are able to set the output desired on theproportional valve using the handwheel. The further you turn the hand-wheel clockwise, i.e. the further you close the proportional valve, thegreater the output will be.

3.9.6 Manual VolumeControl


A820062_03_0208D3–50

The other components of this machine are described on the followingpages. The summary at the start of this chapter will show you wherethe various components are located on the machine. The symbols usedon the other components are described in one of the preceding sections.

The following components may be described here, depending on theequipment on your machine.-- Flushing water pump-- End hose-- Vibrator-- Hydraulic fluid radiator-- High-pressure water pump

NoteFurther control devices and components are described in the“Hydraulic Control Devices” section on page 3–42 and the“Electrical Control Devices” section on page 3–15.

The flushing water pump generates a maximum water pressure of 368psi (25 bar) and a maximum water delivery rate of 42 gallons perminute (160 liters per minute).

1

2

3

Flushing Water Pump (Located on Top of Water Tank)

1 Water hose connection2 Hydraulic motor3 Flushing Water pump

3.10 Other Components

3.10.1 Flushing Water Pump


A820062_03_0208D 3–51

The machine is fitted with a 3 or 4 m long end hose depending on themodel. The maximum permitted end hose length is shown on the boomrating plate. The push--in tubes for the end hose catch brackets areindicated by a plate on the last arm for the end hose length specified.

22500301

1

2

3

End Hose

1 Push-in tube for 3 meter end hose2 Push-in tube for 4 meter end hose3 Plate indicating length of end hose

DangerIt is forbidden, under normal conditions of use, to extend the end hoseor to fit an end hose longer than that specified on the rating plate. Themachine can tip over if you use a longer end hose.

3.10.2 End hose


A820062_03_0208D3–52

NoteEnd hoses may not be fitted with any extension coupling, outlet shoesor other dangerous outlet fitting. However, you can use the modifiedPutzmeister end hose with a flow restrictor if you wish to achieve auniform flow of concrete for filling hollow blocks.

32500601

1

2

3

4

Modified Putzmeister End Hose With a Flow Restrictor

1 Rubber protective sleeve2 Modified end hose3 Push-in spout4 Flow restrictor

DangerThe modified end hose with a flow restrictor may only be used forfilling hollow blocks. The rubber protective sleeve must always bepulled fully down over the push--in spout, whether or not you are usingthe flow restrictor. The end hose may no longer be used if theprotective sleeve is damaged or missing.


A820062_03_0208D 3–53

NoteThe end hose is permanently exposed to high loads and severe wear. Itis, therefore, possible that a heavily worn end hose may tear at thepush--on connection. The retaining rope prevents the end hose fromfalling.

3

4

1

2

Retaining Rope on the End Hose

1 Snap hook2 Retaining rope3 Push-on connection4 Hose clamp

DangerThe retaining rope prevents the end hose falling if it tears away or ifthe coupling is opened. The end hose must therefore always be securedby a retaining rope.

The retaining rope must be passed around one of the clamping bolts onthe hose clamp and secured to the boom by the snap hook. Fasteningthe retaining rope to the coupling is prohibited as otherwise the endhose would fall when the coupling was opened.

Check the retaining rope for damage every day. A damaged retainingrope must be replaced by a new retaining rope immediately.


A820062_03_0208D3–54

The vibrator is bolted to the grill. It causes the grill to vibrate and thusprevents bridges forming on the grill, particularly in the case of verystiff concrete. The vibrator is electrically driven and its connector mustbe plugged into the appropriate round socket on the side of the electriccontrol cabinet. The vibrator is switched on and off either at theelectric control cabinet or on the control panel by the steps.

1

2

3

4

Vibrator

1 Grill2 Vibrator3 Supply cable4 Plug

3.10.3 Vibrator


A820062_03_0208D 3–55

The machine is fitted with two hydraulic fluid radiators. Each radiatorhas its own fan. Some of the hydraulic fluid in the machine first flowsthrough these radiators before returning to the reservoir. The fans onthese radiators switch on once the hydraulic fluid reaches a temperatureof 131 _F (55 _C) at the main hydraulic pump.

2

1

3

4

Hydraulic Fluid Radiator

1 Control cabinet symbol for the hydraulic fluid radiator2 Hydraulic fluid return circuit3 Fan4 Hydraulic fluid supply circuit

3.10.4 Hydraulic FluidRadiator


A820062_03_0208D3–56

NoteYou may switch on both fans at any time using the toggle switch on thecontrol cabinet, whatever the fluid temperature, should you wish tocool the hydraulic fluid as a precautionary measure before it hasreached 131 _F (55 _C). The green indicator lamp on the controlcabinet will light up as soon as a temperature of 131 _F (55 _C) isreached, or if you have switched on the fans.

Leave the truck engine running during breaks in pumping or whenpumping is completed until the fan motors switch themselves off.

The hydraulic fluid is also cooled by the water in the water box. Thehydraulic fluid warms up the piston rods for the drive cylinders. Theseare flushed, and thus cooled, by the water in the water box on eachstroke movement. This also cools the hydraulic fluid. The water in thewaterbox should be flushed and refilled daily.

A820062_04_0208D 4–1

4 Travel


4.1 Driving 4–2

4.2 Towing 4–4

4.3 Loading 4–8

Travel

A820062_04_0208D4–2

The truck-mounted concrete pump may be driven on public highwaysonly if the vehicle and driver are properly licensed.

Prior to driving the truck, perform the following actions:• Check that the vehicle is safe to drive (lighting, brakes, tirepressures, etc.).

• Verify that the following items stored on the truck are properlysecured:-- Delivery hoses-- Delivery pipes-- Clamps-- Tools-- Outrigger pads-- Cable remote control box and cable

• Verify that the outrigger legs are secured in the transport position.

DangerTo prevent the outriggers from accidentally extending while the truck ismoving, close the hydraulic shut--off valves in the outrigger system andensure that each outrigger leg snaplock is secured by a spring pin.

• Ensure that the truck maximum allowable weight limits are notexceeded. Also ensure that all local or state weight limits are notexceeded.

• Check that the oil and water reservoirs are securely closed and notleaking.

• Verify that PTO switch in truck cab is in DRIVE position. If not,depress clutch pedal, start engine, and flip PTO switch to DRIVEposition.

• Do not drive the unit with concrete in the hopper.• Remove all concrete delivery line components from the pump.• Verify that the boom is in its stowed position (i.e., not unfolded).

If you have to drive in reverse, perform the following actions:• Always ask for a marshaller to guide you.• Agree upon clear hand signals with the marshaller before backingup.

• If necessary, have the route blocked or secured by assistants.• Have the site management arrange for the removal of any materialsor equipment that hinder your approach.

• Ensure that pusher axle is in raised position.

4.1 Driving

4.1.1 Prior to Driving

4.1.2 Driving in Reverse

Travel

A820062_04_0208D 4–3

Due to the size and weight of the truck, observe the followingprecautions when driving:• Keep an adequate distance from slopes and pits.• Only drive over arches, bridges or other supporting structures if theload-bearing capacity is adequate.

• Be aware of the height of the truck in height restricted areas (i.e.,underpasses, under bridges, etc.).

• Be aware of the elevated position of the truck’s center of gravitywhen travelling on a slope and on ascending or descending routes.

DangerThe truck may never be driven with the placing boom unfolded. Thismay cause the truck to tip over.

12000100

Never drive the truck with the boom unfolded.

4.1.3 During the Journey

Travel

A820062_04_0208D4–4

The truck-mounted concrete pump may only be towed in accordancewith the truck manufacturer’s rules. Use the towing equipmentprovided. As shown in the diagram below, a coupling is fitted on thefront of the truck for breakdown rescue or towing the truck:

CautionOnly use the towing eye on the rear of the truck for assistance on theconstruction site if a tow-bar cannot be fitted to the front of the truck.Never tow the truck by the pump unit or the hopper.

Tow coupling on the front of the truck

4.2 Towing

Travel

A820062_04_0208D 4–5

40000204

CautionIf you wish to tow the machine from the towing eye on the rear swing-ing support leg, the swinging support leg must be swung fully in, andthe direction of towing must be along the truck axis. Serious damagemay be caused to the boom pedestal, the swinging support leg and theslewing cylinder if the swinging support leg is swung out, or if you towat an angle.

Make sure that the towing rope or the tow--bar does not damage thehopper or other parts of the bodywork if you use the towing eye nearthe hopper.

Travel

A820062_04_0208D4–6

10000400

Towing eye on the rear of the truck

You must use the towing eye on the rear of the truck to tow the truckfrom the rear.

40000203

Towing eye

The towing eye on machines with TRS 60 or TRS 70 boom pedestals ismounted over the compartment housing the rear support.

Travel

A820062_04_0208D 4–7

40000201

Towing eye on the support cylinder

The lifting eye on the support cylinder may be used as the towing eyeon M 42 and larger machines.

40000202

Towing eye at the rear of the swinging support leg

The towing eye on machines with TRDI 60 or TRDI 70 boompedestals is mounted on the rear of the swinging support leg.

Travel

A820062_04_0208D4–8

The standard slinging hooks fitted to the machine are there forassembly purposes only. Slinging hooks suitable for lifting thecomplete machine can be ordered on a new machine and may, possibly,be retro--fitted to an old machine. If your machine is fitted withsuitable slinging hooks, they will be identified as follows:

10002400

Plate for slinging hooks

Suspended loadRaised loads may fall if they are not loaded properly or if the slingsand hooks are damaged.You should, therefore, never walk under suspended loads.

CautionThe machine may only be loaded by crane if it is equipped withsuitable slinging hooks. Lifting equipment, lifting tackle, supports andother auxiliary equipment shall be safe in use and operation. Makesure that the loadbearing capacity is adequate.

10000600

Do not lift the machine by the assembly slinging points

4.3 Loading

A820062_05_0208D 5–1

5 Operation


5.1 Preliminary Information 5–2

5.2 Function Checks 5–3

5.3 Setup 5–7

5.4 Boom Movements 5–27

5.5 Hand Signals for Boom and Pumping Operations 5–33

5.6 Extending the 36Z 4-Section Boom 5–34

5.7 Pumping Operations 5–40

5.8 Cleaning 5–50

5.9 Teardown 5–65

5.10 Pumping Concrete with the Emergency Stroke Kit 5–72

Operation

A820062_05_0208D5–2

Before attempting to place material with the truck-mounted concretepump, operators must be thoroughly trained in its operation. Beforeusing the truck-mounted concrete pump, complete the following steps:• Perform routine truck maintenance as outlined in your truck owner’smanual.

• Completely inspect the truck-mounted concrete pump for worn ordamaged parts, loose bolts, missing parts, etc.

• Perform periodic maintenance on the truck-mounted concrete pump,as outlined in the Maintenance section of this manual.

WarningRead and comply with all safety rules, notes, and warnings containedin this manual. This is absolutely essential to the safe, efficientoperation of the truck-mounted concrete pump.

NotePrior to starting up the machine, you should become so familiar withthe machine that damage and accidents cannot occur. Every time youuse the machine, you accept full responsibility for the safety of anyonelocated in the machine’s danger zone. You are therefore under anobligation to ensure that the machine is completely safe in operation.

5.1 PreliminaryInformation

Operation

A820062_05_0208D 5–3

You should check the following functions before you begin using themachine on the construction site

The basic precondition for problem--free operation of the machine is aproperly functioning pump.

Check for the proper switchover function of the delivery pistons andthe transfer tube at various speeds of the drive motor and settings of theflow regulator.

20500405

Check the Proximity Switch

Check whether the drive cylinders are switching over automatically assoon as the pistons of drive cylinder I (on the right in the direction oftravel) approach the two forward or rear proximity switches. Theassociated indicator lamp on the distributor casing should light upbriefly. If one of the indicator lamps does not light up, the associatedproximity switch is defective.

Press the switchover button on the remote control at a slow deliverypiston speed and hold it down.The delivery pistons should move to their end positions. Strokecorrection is automatic and is complete when both delivery pistonscome to a halt (may be seen in the water box).

Fully close manual volume control valve (by rotatingcounterclockwise) to have pump operate at maximum speed. Measurethe stroke time over ten individual strokes. The value determined,divided by 10, must comply with the ratings on the Pump test readingsheet following the machine card in the Technical Data section.

5.2 Function Checks

5.2.1 Pump Functions

Switchover

Proximity Switch

Stroke Length

Stroke Time

Operation

A820062_05_0208D5–4

Dirty filters reduce the fluid flow considerably so that damage mayoccur in the hydraulic system.

10300200

VacuumMeter -- The filter elementmust be replaced if the vacuummeter indicatoris in the red zone at more than 85˚F (30˚C) fluid temperature and the fasteststroke time.

Pressing Down the Red Button on the Boom Filter

1. Warm the hydraulic fluid up to normal operating temperature (>120˚F (50˚C)).

2. Set the maximum pumping rate.

3. Press in the red button on the boom filter if it is sticking out.

NoteYou must replace the boom filter element if the red button pops outagain after a short time.The boom filter is OK if the red button remains depressed.

Environmental protectionComply with the waste disposal regulations in force for your area whenchanging the fluid filters.

5.2.2 Filter Functions

Vacuum Filter

Boom Filter

Operation

A820062_05_0208D 5–5

It is only possible to intervene rapidly in the event of danger if all theEMERGENCY SHUT--DOWN buttons are functioning.

CautionThe machine is no longer safe in operation if the EMERGENCYSHUT--DOWN button is defective, as you will no longer be able toswitch the machine off quickly enough if danger threatens.You must therefore inspect the function of the EMERGENCYSHUT--DOWN buttons and the lever position for the boom valves (see“Function check on the boom control unit”) before starting work eachtime.

DangerThe machine is only switched off electrically when the EMERGENCYSHUT--DOWN button is pressed. Although this causes all theelectrically actuated hydraulic valves to be switched off, anuncontrolled sinking of the boom caused by leakages in the hydraulicsystem, for instance, cannot be prevented in this way.

Furthermore, the EMERGENCY SHUT--DOWN circuit has noinfluence on the agitator pump (i.e., the agitator continues to rotate,despite the EMERGENCY SHUT--DOWN button having been pressedin).

5.2.3 EMERGENCYSHUT-DOWNFunction

Operation

A820062_05_0208D5–6

10500200

Press -- Lock EMERGENCY SHUT--DOWNTurn -- Unlock EMERGENCY SHUT--DOWN

1. Switch the pump on.

2. Operate a boom function.

3. Press one of the EMERGENCY SHUT--DOWN buttons.The pump and the boom must come to a halt immediately.

4. Check all EMERGENCY SHUT--DOWN buttons on the machineand on the remote control in the same way.

You may only operate the machine if the boom control unit is fullyfunctional.

1. Switch on the radio or cable control.

2. Operate the boom control levers briefly several times whileobserving the levers on the boom control unit. The lever for theboom valve operated and the lever for the operating mode selectorvalve must move each time.

NoteAs soon as you release the boom control levers on the remote controlunit, the levers for the boom arm valves previously actuated and for theoperating mode selector valve must return to the central position (zeroposition).

The reactions of the operating mode selector valve on the boom controlunit are delayed by approximately 0.8 seconds if you use the cablecontrol or radio.

EMERGENCYSHUT-DOWN Button

5.2.4 Function Check onthe Boom ControlUnit

Operation

A820062_05_0208D 5–7

5.3 Setup

Prior to operating the truck-mounted concrete pump, perform apre-operation inspection by checking the following items:

NotePerforming a pre-operation inspection prevents downtime and helpsmaintain the truck-mounted concrete pump in proper workingcondition between scheduled maintenance checks.

WarningDefective components, structural damage, missing parts or equipmentmalfunctions, jeopardize the safety of the operator and other personneland can cause extensive damage to the machine. A poorly maintainedmachine could become the greatest operational hazard you mayencounter. It should be a common practice that the operator perform athorough walk-around inspection before each day’s operation of theconcrete pump.

NoteAll water, oil, and fuel levels should be checked and topped off asnecessary. The machine must be level when you check the functionalfluids. The boom and the supports must be retracted. The water box onconcrete pumps must be full during operation, even if there is a risk offreezing.

DangerOils, fuel and other functional fluids may be injurious to health oncontact with the skin, etc.You must, therefore, always wear personal protective clothing andequipment when you are handling toxic, caustic or other functionalfluids that are injurious to health and always take note of themanufacturer’s information.

DangerIf any discrepancy is noted during the pre-inspection, attach a sign atthe control panel stating “DO NOT OPERATE” and repair thediscrepancy before operating the truck-mounted concrete pump.

5.3.1 Pre-OperationInspection

Operation

A820062_05_0208D5–8

• Overall machine condition:-- External structural damage-- Wheel lug nuts (missing or loose)-- Wiring and brake lines-- Condition of tires (tears, cracks or cuts, inflation)-- Missing decals, placards, warning signs-- Missing, broken or damaged parts, bolts and nuts-- Control panel, switches, gauges, volume control-- Electrical system for frayed or broken wires or loose connections

• Engine-- Fuel level-- Oil level-- Mounting (bolts, wiring, hoses)-- Fuel or oil leaks-- Belts (fan, alternator)

• Battery-- Battery condition-- Cables and connections (ground connection)-- Battery hold down security

• Hydraulic System-- Hydraulic leaks-- Loose or damaged hoses, tubing-- Fluid level, hydraulic tank breather cap. Refill only with an

appropriate hydraulic fluid listed in the “RecommendedLubricants” section on page NO TAG.

-- Hydraulic valves and control levers-- Cleanliness of hydraulic fluid. Non-milky, bright in color-- Hydraulic cylinders, S--tube shift and delivery cylinders

• Hopper-- Grate in place, not damaged-- S--tube-- Remixer agitator, drive motors (if equipped)-- Outlet cleanliness-- Lubrication

• Boom-- Lubrication-- Missing, broken or damaged parts, bolts and nuts-- Hydraulic leaks-- Loose or damaged hoses, tubing

Operation

A820062_05_0208D 5–9

Prior to setting up the truck-mounted concrete pump, perform thefollowing steps:

NoteAs a rule, the site management determines the setup site for themachine and prepares the site accordingly. However, the machineoperator is responsible for setting up the machine safely. The machineshould only be set up on level ground. Inspect the proposed sitecarefully and reject the setup site if you have any doubts about thesafety of the site.

1. Walk the approach route before you drive it. Ask for someone togive you directions if you have to drive the truck in reverse.

2. Maintain a safe distance from pits, slopes, trenches, etc., whenapproaching the setup site and when setting up. Check thecondition of the soil or flooring where the machine will bepositioned. As shown in the diagram below, the force transferredinto the ground by each outrigger is distributed through the groundin a conical pattern at a 45˚ angle. This imaginary cone must notexit through the wall of the pit. Ensure that you maintain a safe

distance from any pits (i.e., at least “a”), as mentioned below:

A. If the ground has a good loadbearing capacity, maintain aminimum clearance of “a” from a pit even if the pit is shallow.The minimum clearance “a” from a pit for machines• up to 26,000 lbs permissible gross weight, is 3.3 feet (1 m);• over 26,000 lbs permissible gross weight, is 6.6 feet (2 m)

5.3.2 Preliminary Setup

Operation

A820062_05_0208D5–10

45˚

a

Minimum Clearance “a” From a Pit

B. If the ground does not have a good loadbearing capacity,maintain an additional safety clearance “A” from a pit. Asshown in the diagram below, the additional safety clearance“A” from a pit:• for loose, backfilled ground is equal to twice the pit depth

(i.e., A≧ 2× pit depth T),• for compact, solid ground is equal to the pit depth

(i.e., A≧ 1× pit depth T).

Operation

A820062_05_0208D 5–11

A≧2×T A≧1×T

T

A

12100402

Additional Safety Clearance “A” From a Pit

Permissable gross weight of machine = 45,000 lbs(Therefore the minimum distance from the pit “a” = 6.6 feet)

Type of ground = loose, backfilled; depth of pit (T) = 3 feet(Therefore the additional safety clearance from the pit “A” = 2 x 3 ft = 6 ft)

Required distance from pit (i.e., greater of “a” (6.6 ft) and “A” (6 ft)) = 6.6 ft

Permissable gross weight of machine = 23,000 lbs(Therefore the minimum distance from the pit “a” = 3.3 feet)

Type of ground = compact, solid; depth of pit = 2 feet(Therefore the additional safety clearance from the pit “A” = 1 x 2 ft = 2 ft)

Required distance from pit (i.e., greater of “a” (3.3 ft) and “A“ (2 ft)) = 3.3 ft

Calculation Example 1

Calculation Example 2

Operation

A820062_05_0208D5–12

3. Ensure that there is clearance to extend the outrigger legs. Theoutrigger legs must be fully swung out or extended. As shownbelow, the outrigger’s danger zone is the zone in which the

outriggers are swung out or extended:

12100801

The Outrigger Legs Must Always Be Fully Swung Out and Extended

The Outrigger’s Danger Zone

Danger of crushingSince there is a danger of crushing in the swing--out and extension zonefor the outriggers, you should secure this area and keep it underconstant observation. You must halt work immediately and press theEMERGENCY SHUT--DOWN button if anyone enters this danger zone.

Operation

A820062_05_0208D 5–13

4. As shown in the diagram below, ensure that there are no voids or

other ground irregularities under the outrigger feet:

22102802

No Voids or Other Ground Irregularities Under The Outrigger Feet

CautionDo not bridge voids or other ground irregularities with support blocksor timber blocks, since these blocks may break if a point load is appliedto them. If these blocks break, the machine will not have the necessarystability and may tip over.

5. As shown in the diagram below, ensure that the outrigger feet areset up on level supporting ground:

22102803

Outrigger Feet Should Only Be Set Up on On Level Supporting Ground

Operation

A820062_05_0208D5–14

6. Verify that the machine is supported in accordance with the cornerbearing loads and the loadbearing capacity of the supporting ground(permissible ground pressure), by performing the following steps:

A. Ask site management for the maximum permissible groundpressure (i.e., loadbearing capacity of the supporting ground).

B. Determine whether the outrigger support area is adequate bycalculating the maximum possible ground pressure that eachoutrigger leg can exert using the following equation:

Max possible ground pressure =Machine corner bearing load

Max. possible ground pressure =Support area

lbs

kN

t

The Corner Bearing Load is Stated on Each Outrigger Leg

NoteThe support area is adequate if the maximum possible ground pressureis less than the maximum permissible ground pressure.

C. If the maximum possible ground pressure is greater than themaximum permissible ground pressure, then it is necessary toincrease the support area under the outrigger feet withPutzmeister support blocks or timber blocks (refer to “timberblock length” table on page 5-16).

Corner Bearing Load

Operation

A820062_05_0208D 5–15

12100501

Putzmeister support blocks are made of multi--ply glued timber. The supportblocks are 23.6 in x 23.6 in (60 cm x 60 cm) in size.

DangerAlways use 4 timber blocks with a cross--section of 6 in x 6 in.(15 cm x 15 cm) each and of the length shown in the table on the nextpage.. Place the 4 timber blocks together beneath the support block asshown. The support block and the timber blocks must always be freefrom grease, oil, ice, etc., as otherwise the support leg could slip off.

12100502

Support Block

Operation

A820062_05_0208D5–16

The table below shows the minimum length of the timber blocksrequired.

Corner bearing load in kN(see support leg) 50 75 100 125 150 175 200 225 250 275 300 325 350 375 400

Metric Tons(1000Kg=2205Lbs) 5.0 7.5 10.0 12.5 15.0 17.5 20.0 22.5 25.0 27.5 30.0 32.5 35.0 37.5 40.0

Pounds 11,250 16.875 22,500 28,125 33,750 39,375 45,000 50,625 56,250 61,875 67,500 73,125 78,750 84,375 90,000

Permissible groundpressure kN/m2

(Lb/in2)15 cm x 15 cm (6 in x 6 in) timber block lengths in cm (in)

Undisturbed soil 100(14.5)

84(33)

125(50)

167(66)

209(83)

250(99) Supporting ground is not

Asphalt 200(min. 20 cm thick) (29)

84(33)

105(42)

125(50)

146(58)

167(66)

Supporting ground is notsuitable for outriggers

Hardcore 250(compacted) (36.3)

84(33)

100(40)

117(46)

134(53)

150(60)

167(66)

Clay, coarse clay 300(firm) (43.5)

84(33)

98(39)

112(44)

125(50)

139(55)

153(61)

167(66)

Mixed stone 350(firm) (50.8)

Use Putzmeistersupport blocks

84(33)

96(38)

108(43)

119(47)

131(52)

143(57)

155(61)

167(66)

Layered gravel 400(firm) (58)

support blocks23.6in x 23.6in(60cm x 60cm)

84(33)

94(37)

105(42)

115(46)

125(50)

136(54)

146(58)

157(62)

167(66)

500(72.5)

(60cm x 60cm)without additionaltimber blocks

75(30)

84(33)

92(37)

100(40)

109(43)

117(46)

125(50)

134(53)

750(109)

73(29)

78(31)

84(33)

89(35)

Rock 1000(fractured, weathered) (145)

NoteYou should use the next higher value if the corner bearing load is notexactly the same as the value specified in the table (e.g. actual cornerbearing load of the machine = 180 kN; you must take the timber blocklength from the 200 kN column from the table).

Length of the TimberBlocks Required

Operation

A820062_05_0208D 5–17

Corner bearing load in kN(see support leg) 50 75 100 125 150 175 200

Metric Tons(1000Kg=2205Lbs) 5.0 7.5 10.0 12.5 15.0 17.5 20.0

Pounds 11,250 16.875 22,500 28,125 33,750 39,375 45,000


(Lb/in2)

15 cm x 15 cm (6 in x 6 in) timber block lengths incm (in)


84(33)

125(50)

167(66)

209(83)

250(99)


84(33)

105(42)

125(50)

146(58)

167(66)


84(33)

100(40)

117(46)

134(53)


84(33)

98(39)

112(44)



84(33)

96(38)



84(33)

500(72.5)

( )without additionaltimber blocks

Soil type: firmly layered gravel

Permissible ground pressure 400 kN/m2

Machine corner bearing load 150 kN (15 metric tons or 33,750 lbs)

Timber block length not required

In this example it is sufficient to place Putzmeister 60 cm x 60 cm(23.6 in x 23.6 in) support blocks beneath the support feet.

Example 1

Operation

A820062_05_0208D5–18

Corner bearing load in kN(see support leg) 50 75 100 125 150 175 200

Metric Tons(1000Kg=2205Lbs) 5.0 7.5 10.0 12.5 15.0 17.5 20.0

Pounds 11,250 16.875 22,500 28,125 33,750 39,375 45,000


(Lb/in2)

15 cm x 15 cm (6 in x 6 in) timber block lengths incm (in)


84(33)

125(50)

167(66)

209(83)

250(99)


84(33)

105(42)

125(50)

146(58)

167(66)


84(33)

100(40)

117(46)

134(53)


84(33)

98(39)

112(44)



84(33)

96(38)



84(33)

500(72.5)

( )without additionaltimber blocks

Soil type: compacted hardcore

Permissible ground pressure 250 kN/m2

Machine corner bearing load 150 kN (15 metric tons or 33,750 lbs)

Timber block length at least 100 cm (40 inches)

In this example you must place 4 timber blocks with a cross--section of15 cm x 15 cm (6 in x 6 in) and a length of at least 100 cm (40 in) beneaththe support feet in addition to the Putzmeister 60 cm x 60 cm (23.6 in x23.6 in) support blocks.

7. Check the clearance for extending the placing boom.

8. Ensure that the setup site is adequately ventilated. Exhaust gasescan be fatal.

Danger of poisoningVehicle exhaust gases contain constituents which can be lethal or car-cinogenic. Set the machine up at an adequately ventilated site or ventthe exhaust gases away from where you are working.

Example 2

Operation

A820062_05_0208D 5–19

9. With truck engine running, transmission in neutral, and parkingbrake on, engage concrete pump power take-off (PTO), byperforming the following steps:

NoteIf your truck engine is equipped with electronic diesel control (EDC)you must apply the parking brake before you switch on the power take--off. Otherwise you will not be able to increase engine speed duringpumping operations. This is also the case if you release the parkingbrake and apply it again while the power take--off is switched on.

CautionThe following points must be complied with to prevent damage whenusing power take-off gearboxes:– The transmission must be in neutral when the power take-offgearbox is switched on or off.

– If the engine was shut down during pumping operations and yourtruck has a manual transmission, you must depress the clutch beforestarting it up again.

A. Position concrete pump PTO switch (located on right side ofdriver’s seat) to “PUMP” position (PTO engaged).

B. Verify that green “PUMP” light illuminates.

C. If your vehicle has a manual transmission, perform these steps:• Push in clutch pedal (clutch disengaged).• Place truck transmission in proper pumping gear.• Let clutch pedal out (clutch engaged).

D. If your vehicle has an automatic transmission, shift selectorfrom “N” (Neutral) to “D” (Drive). The display indicates “4”signifying that truck transmission is in 4th gear lock-up (i.e.,the truck transmission will remain in 4th gear). If engine isswitched off or transmission shifted to Neutral, repeat Step 9 toreset interlocks for 4th gear lock-up PTO operation.

NoteThe truck engine will automatically throttle up approximately 200 RPMwhen the PTO’s are engaged and the E--stops are cleared.

Operation

A820062_05_0208D5–20

Depending on your machine’s equipment, you are able to operate it-- using radio remote control,-- using cable remote control, or-- directly from the machine in emergency operation.

DangerBefore starting to use the remote control, press the EMERGENCYSHUT--DOWN button on the remote control and shift all control andmonitoring devices on the remote control to the “0” position. Theboom or the pump can otherwise execute unintended movements assoon as the remote control is switched on.

CautionCarry the remote control in such a way that no control elements can beactuated unintentionally. Do not damage the remote control cable. In-correct functions may otherwise occur.Never put the remote control down when the machine is in ready mode.If this cannot be avoided in exceptional circumstances, press theEMERGENCY SHUT--DOWN button in, disconnect the remote controland lock the remote control unit away in the driver’s cab.

10. If using a cable remote control system, perform the following steps:

NoteYou can only execute boom movements in black and white with thecable remote control (i.e., the boom always moves at its maximumspeed, no matter how much you move the boom control lever).

DangerBlack/white control can lead to jerky movements and significantswaying of the boom, which represents a high risk of an accident to theoperator guiding the hose. Flip the toggle switch boom speed to thesnail symbol and the rotary controller to “0” before beginning to usethe cable remote control. This ensures that the first boom movementsafter the remote control is switched on will be executed slowly and youwill be able to get used to them.

5.3.3 Remote ControlSetup

Operation

A820062_05_0208D 5–21

A. Verify that remote cable is connected between the electriccontrol box and cable remote control box.

NoteOn some control cabinets, the socket into which the cable remotecontrol is plugged is located on the control cabinet casing. On somecontrol cabinets the socket is fixed to the truck superstructure andconnected to the control cabinet by a cable.

10504600

Connecting the Cable Remote Control

B. Verify that Local-Remote switch on electric control box is in“Remote” position.

C. At cable remote control, perform the following steps:• Verify that all function switches are off.• Twist emergency stop (E-stop) button to allow it to pop out.

D. Ensure electric control box and other E-stops are released.

NoteThe horn/outrigger/reset switch is used to clear the E-stop mode.Clear the E-stop mode by pushing the horn switch up once. The firstpress clears the E-stop. The second and subsequent presses blow thehorn. If the horn will not blow, recheck cable connections, E-stopbuttons, and power supplied to the electric control box.

Operation

A820062_05_0208D5–22

11. If using a proportional radio remote control system, perform the

following steps:

NoteProportional control means:– The boom moves slowly on a small movement of the boom controllever.

– The boom moves at its maximum speed on a large movement of theboom control lever.

A. Verify that radio receiver is connected to electric control box.

B. Verify that Local-Remote switch on electric control box is in“Remote” position.

C. Ensure transmitter has charged battery inserted.

D. Release E-stop button, by twisting button to allow it to pop out.

E. Verify that all functions switches are off.

F. Turn transmitter power switch on.

G. Ensure electric control box and other E-stops are released.

NoteThe horn/outrigger/reset switch is used to clear the E-stop mode.Clear the E-stop mode by pushing the horn switch up once. The firstpress clears the E-stop. The second and subsequent presses blow thehorn. If the horn will not blow, recheck cable connections, E-stopbuttons, and power supplied to the electric control box.

Operation

A820062_05_0208D 5–23

5.3.4 Outriggers Setup

12. On cable or radio remote control, place horn/outrigger/reset switchin outrigger position.

DangerYou must have read the safety regulations and have completed theoperations for setting up the machine before you begin setting out themachine outriggers. The machine outriggers may only be used under thefollowing conditions:– the pump drive engine is running;– the power take--off is engaged (i.e., the machine is set to pumpingoperations);

– the “Outrigger” function has been selected at the remote control oron the control block.

It is absolutely forbidden to move the outriggers manually (mechanically).

12101600

Do not move the hydraulic support legs manually

Operation

A820062_05_0208D5–24

13. As shown in the diagram below, unlock the outrigger legs byperforming the following steps:

A. Pull out the spring pin (1).

B. Pull the lever on the snaplock upwards (2).

12100101

1

2

Outrigger snaplock -- You must unlock the outrigger legs before you are able toextend them or swing them out.

NoteExtendable support legs are automatically locked by the snaplock oncethe support leg is fully extended.Once the legs are locked, replace the spring pin. The snaplock cannotnow be opened unintentionally and the support leg remains locked inthe end position.

The snaplock has no function once swing--out support legs have beenswung out. Do not replace the spring pin; in this way the supports willbe locked automatically when they are swung back.

Before driving off, make sure that all the snaplocks are secured by aspring pin.

DangerDo not attempt to reposition any outrigger unless placing boom is instowed position. The placing boom will not operate when theoutriggers are activated.

Operation

A820062_05_0208D 5–25

14. Use the left outrigger controls to lower the left rear and left frontoutriggers as follows:

A. Extend the left rear outrigger.

B. Lower the left rear outrigger.

C. Extend the left front outrigger.

D. Lower the left front outrigger.

CautionOnly execute one outrigger at a time. Observe leveling bubble andensure that truck remains level as each outrigger is positioned.Stability is jeopardized at a deviation from horizontal of 3_ or more.

32100101

53

d

d

1

Leveling bubble

1 Permissible range of tilt

15. Repeat Step 14 for the right outriggers.

NoteExtend the outriggers one after the other until the truck lifts about 5 cm(2 inches) from the ground. The rear wheels may be in light contactwith the ground in order to achieve “steady pumping”.

Operation

A820062_05_0208D5–26

DangerAll four outriggers must be completely swung out and extended tostabilize the truck-mounted concrete pump placing boom throughswing, unfolding, extending, and elevate functions. Wrong positioningor partial opening of outriggers can cause machine instability and riskof overturning.

DangerUncontrolled movements of the outrigger legs increase the risk of anaccident. They are possible if:– the hydraulic system has not been carefully bled;– pipes or threaded unions are leaking;– there is too little hydraulic fluid in the reservoir;– the switch is defective or dirty.

In this case, the support legs may move as soon as the preselect switchis actuated. Halt work immediately. You can continue working onlyafter the causes have been remedied and perfect functioning of themachine is ensured.

NoteBefore closing the outriggers, ensure that the boom is correctly closedand resting on the support in its housing. To close the outriggers,follow inversely the instructions for opening. When closing thestabilizers, move to a safe position so as not to be hit by the outriggers.

16. After outriggers are positioned, on the radio or cable remotecontrol, return the horn/outrigger/reset switch to its center (off)position to activate the boom controls.

Operation

A820062_05_0208D 5–27

Before you extend the placing boom you must read the safetyregulations and complete the operations to set up the machine.

You may only extend the placing boom once you have set the machine upproperly. Comply with the safety regulations of the country in which youare using the machine in every case.

Prohibited Activities

DangerAvoid the following actions. They overload the placing boom and willlead to damage and jeopardize persons:– lifting and transporting loads;– allowing the placing boom to strike an obstacle;– pushing with the placing boom, in order to move an obstacle out ofthe way, for instance;

– tearing away a trapped end hose by force.

CautionTake note of the working ranges of other machinery that is workingnear you (e.g., cranes, other concrete placing booms, etc.)

5.4 Boom Movements

Prohibited Activities

Overlapping WorkingRanges

Operation

A820062_05_0208D5–28

Extreme weather conditions, such as gales, storms or low temperaturesrestrict the use of the boom, or can even make its use impossible.

Shift the placing boom to the transport position in the event of stormsor bad weather.-- Placing booms with a vertical reach of 42 m or more (M 42 andlarger) may not be operated in winds of force 7 or greater (windspeed 31.1 miles/hr (50 km/hr) and higher).

-- Placing booms with a vertical reach less than 42 m (< M 42) maynot be operated in winds of wind force 8 or more (wind speed38.5 miles/hr (62 km/hr) and greater).

Higher wind speeds jeopardize stability and the safety of structuralelements. There is a risk of lightning strike in the event of storms.

Tower cranes on construction sites generally have wind speedmeasuring equipment, so that you can ask about the wind speed at anytime. If no wind speed measuring equipment is available, you can askthe nearest meteorological office what the wind speed is, or estimatethe wind speed using the following rule of thumb:• In winds of force 7 and greater, green leaves break from trees andthere is a perceptible hindrance to walking in the open.

• In winds of force 8 and greater, small branches break from trees andwalking outside is made significantly more difficult.

The boom may not be used in temperatures below minus 15 _C (+5 F).There is a danger of damage to the steel (brittle fracture) and the sealsthroughout the system at such extreme minus temperatures. Inaddition, such minus temperatures should be considered the realisticlower limit for concrete placement, as it is no longer possible toprepare concrete such that it can achieve its strength without the use ofspecial additives. During cold weather, if hydraulic fluid is not atnormal operating temperature, then boom operation may be sluggish.

5.4.1 Restrictions on Use

Bad Weather andStorms

Cold Weather

Operation

A820062_05_0208D 5–29

22000500

The danger zone when working with the boom is the zone over which the boomis slewed.

DangerThere is a risk of injury from parts of the delivery line falling beneaththe slewing circle of the placing boom. There is a risk of injury fromfalling concrete beneath the end hose.You should therefore secure the danger zone. Keep the danger zoneunder constant observation.You must halt work immediately and press the EMERGENCYSHUT--DOWN button if anyone enters the danger zone.

5.4.2 Danger Zone

Operation

A820062_05_0208D5–30

22000400

Caution in the Vicinity of High--Voltage Lines

DangerA spark can jump across from high--voltage lines even if you justapproach them and this will energize the machine and the surroundingarea. YOU MUST THEREFORE MAINTAIN AT LEAST 17 FEETFROM ANY HIGH-VOLTAGE LINES.

5.4.3 High-Voltage Lines

Operation

A820062_05_0208D 5–31

Sound the Horn First, Then Move

NoteMove the placing boom with cautious operation of the controls.Maintain visual contact with the site of concrete placement.Warn by sounding the horn before you move the boom.

The hydraulic fluid heats up to an average temperature of 140˚-- 158˚F(60˚-- 70˚ C) during operation because of the friction in the lines.When the hydraulic fluid cools, its volume reduces as cold hydraulicfluid has a smaller volume than does hot hydraulic fluid. This causesthe cylinders on the boom, swing--out legs and outriggers to retract alittle, which causes the boom to move and the outrigger feet to sink.

CautionThe boom can move during lengthy pauses in work due to cooling ofthe hydraulic fluid. For this reason you should never leave the boom inthe extended position during breaks in working.In addition, you must keep the outriggers under constant observationwhile the machine is in operation. You may have to readjust the swing--out cylinders and outrigger cylinders.

The extent to which the boom and the truck move depends on theextent to which the various boom and outrigger cylinders have beenextended and the magnitude of the temperature difference in thehydraulic fluid.

5.4.4 Signal of BoomMovements

5.4.5 Temperature-RelatedCylinder Movements

Operation

A820062_05_0208D5–32

The following defects may be the cause of uncontrolled boommovements:-- Malfunctions in the remote control circuit-- Malfunctions on the boom control block-- Lines, threaded unions or boom cylinders leaking-- Defective mono-isolator on the boom cylinder-- Hydraulic system not carefully bled-- Insufficient hydraulic fluid in the reservoir-- Cooling of the hydraulic fluid

In this case, the boom may move as soon as the remote control isswitched on. Halt work immediately. You can continue working onlyafter the causes have been remedied and perfect functioning of themachine is ensured.

NoteWhatever the reason for the uncontrolled movements of the boom, youmust halt the work on site and have the cause of the breakdowndetermined and rectified by qualified personnel.

DangerIn no event should you first press the EMERGENCY SHUT--DOWNbutton if the boom starts uncontrolled movements. Should you do thisyou will have no ability to counteract the movement.

You must proceed as follows if the boom starts uncontrolledmovement:

1. Counter the uncontrolled movement immediately and attempt tosteer the boom out of the danger zone and bring it to rest undercontrol.

2. If the uncontrolled boom movement continues, despitecountermeasures, press the EMERGENCY SHUT--DOWN button.

NoteRepeated practice is required to ensure that it will be possible to imple-ment the measures described above in an emergency.

5.4.6 Uncontrolled BoomMovements

Countermeasures

Operation

A820062_05_0208D 5–33

Pump operators and persons guiding them must agree on unambiguoushand signals before commencing work. Suggestions for the mostimportant hand signals are made in this section. They are based onACPA Safety Manual Hand Signals. The direction of movement isspecified from the machine operator’s direction of view.

5.5 Hand Signals forBoom and PumpingOperations

Operation

A820062_05_0208D5–34

Proceed in the sequence specified to extend the 36Z 4-section boom.The boom must be folded in the reverse sequence.

NoteYou must unfold the arm assembly to the side of the truck to be able toachieve the lowest possible unfolding height of 28.5 ft (8.7 meters).

CautionThe hydraulic fluid is warm when you fold the arm assembly. It thencools and the pressure in the cylinder drops. If you then raise arm 1,the remaining arms become depressurized and may fall down. You musttherefore draw the arm assembly together briefly before raising arm 1.

Always observe the specified sequence for folding and unfolding theboom. Failure to comply with the sequence may allow the crank leverin the C hinge to compress the delivery line, adjacent hydrauliccylinders, or other components.

Danger

Arms 3 and 4 must not be moved behind the C hinge when unfolded orpartially unfolded during the entire boom operation. In this armposition, the rod side C cylinder hydraulic pressure is so high that thepressure limiting valve responds and the boom will gradually slump.

There is also a risk of uncontrolled boom movements.

5.6 Extending the 36Z4-Section Boom

Operation

A820062_05_0208D 5–35

1. As shown below, draw the arm assembly together by: (1) droppingarm 2 and 4 briefly, and (2) raising arm 3 briefly.

Drawing the Arm Assembly Together

2. As shown below, raise arm 1 approximately 45˚.

45˚

Operation

A820062_05_0208D5–36

3. As shown below, slew the placing boom approximately 180˚.

180 ˚

CautionTake care when unfolding arm 2 that you do not damage the driver’scab or other elements. It may be necessary to raise arm 1 higher.

4. As shown below, raise arm 2 until it is almost vertical.

Operation

A820062_05_0208D 5–37

CautionBefore you unfold arm 3, you must open arm 4 by approximately 15_,so that the boom tip is approximately 3.28 ft (1 meter) away from theC hinge (hinge between arm 2 and arm 3). The crank lever on the Chinge will be forced against the bend at the boom tip if you do notfollow this instruction.

5. As shown below, open arm 4 approximately 15_.

15˚

6. As shown below, unfold arm 3 approximately 45˚.

45˚

Operation

A820062_05_0208D5–38

7. As shown below, unfold arm 4 enough to allow you to unlock theend hose.

8. As shown below, unlock the end hose by pulling the two lockinglevers downwards.

Operation

A820062_05_0208D 5–39

1

A820062_05_0208D12

Impermissible Working Range

1 Range in which work with the end hose is not permitted

CautionThe end hose may not be shifted behind the vertical.

5.6.1 ImpermissibleWorking Range

Operation

A820062_05_0208D5–40

You must carry out the following operations before you start to pump:-- Set the machine up for work properly (see “Starting Up” section).-- Set the machine supports out properly (see “Supporting theMachine” section).

-- Carry out all necessary function checks (see “Function Checks”section).

-- Extend the boom to the desired working position (see “Extending thePlacing Boom” section).

Dangers to the life and limb of site personnel can arise at many pointsduring pumping operations. You can minimize these dangers byobserving the following notes.

12500500

1

2

1 Maximum end hose length 13.1 ft (4 m)2 Danger zone = 2 × end hose length = 26.2 ft (8 m)

DangerThere is a risk of injury in the area around the end hose if the end hoseswings out violently when starting to pump, after a blockage has beenfreed, or during washing out. This zone is twice the end hose length indiameter.The end hose must be allowed to hang freely.Ensure that nobody is standing in the danger zone. Keep the dangerzone under constant observation.You must halt work immediately and press the EMERGENCYSHUT--DOWN button if anyone enters the danger zone.

5.7 Pumping Operations

5.7.1 Hazards

End Hose Striking Out

Operation

A820062_05_0208D 5–41

12501901

DangerNever bend the end hose over. Never attempt to straighten a bent endhose by increasing the pressure. The end hose must not be inserted inthe concrete. Extension of the placing boom and end hose beyond thelength specified on the boom rating plate is forbidden. The end hosemust be secured against falling.

10800114

Agitator Hopper Escaping Compressed Air

DangerEntrapped air in the delivery line is dangerous as the compressed air isreleased suddenly at the end of the delivery line and the concrete canbe blown out explosively. No air must be sucked in for this reason.You should therefore always fill the agitator hopper with concrete up tothe mixer shaft during pumping operations.

Incorrect Use ofthe End Hose

Sucking in Air

Operation

A820062_05_0208D5–42

To supplement the notes given here, you will find comprehensiveinformation on the following subjects in our “Concrete technology”pamphlet (BP 2158):-- Concrete components-- Properties of freshly--mixed concrete-- Properties and conditions of freshly--mixed concrete when pumping-- Guide to avoid faults-- Specifications and regulations of the “Technical Regulations”

You may request this pamphlet from Putzmeister’s After Salesdepartment should you not already have a copy.

Bouncing Boom

NoteIf the boom bounces very heavily in pumping operations, check thesupport and correct it as required. Calm pumping is achieved if therear wheels are in light contact with the ground. Do this by retractingthe rear support feet until the rear wheels are in ground contact andthen retract the support feet about another .4 inches (1 cm).

If the support is correct, reduce the pump speed or change the boomposition.

The boom can also bounce if air is taken in and compressed in thedelivery line. You should therefore always make sure that the agitatorhopper is always filled with concrete to the mixer shaft and that no airis sucked in.

32202300

Last Arm in a Horizontal Position

5.7.2 Notes on CorrectPumping

Favorable BoomPosition

Operation

A820062_05_0208D 5–43

NoteA horizontal position of the last arm is favorable for pumping.

If the last arm is lower than the horizontal, the concrete in this part ofthe delivery line will flow more quickly as a result of its self--weight.The flow velocity is lower if the arm position is horizontal, and thus thewear on the delivery pipes and the end hose is less.

When the pump is stopped, only the content of the end hose flows out ifthe arm position is horizontal; the content of the delivery line can flowout if the arm position is below the horizontal.

The strokes of the pump cause forces to act along the delivery line andthus along the boom. If the last arm is vertical, the forces also actvertically on the boom end and move the boom up and down. If the armposition is horizontal, the boom is moved forwards and backwards,which causes a light rocking motion.

As shown in the diagram below, the damping valve is used to controlthe switching speed of the transfer tube.

20203903

Hare: Damping Valve Switch Position OpenSnail: Damping Valve Switch Position Closed

NoteYou must close the damping valve when you are pumping softconsistence concrete (snail symbol) as otherwise the transfer tubeswitches over too harshly.

You must open the damping valve (hare symbol) when you are pumpingstiff consistence concrete as the concrete has a damping effect.

Damping Valve

Operation

A820062_05_0208D5–44

The process from the start of concrete pumping to the time at which acontinuously flowing concrete stream exits from the end hose is knownas starting to pump. The entire delivery line must be wetted at the startof pumping operations by performing the following steps:

Starting Pumping with Thin Concrete

1. Insert two sponge balls into the delivery line through the wash--outport.

2. Pour approximately 0.65 yd3 (0.5 m3) thin concrete into the hopper.

3. Switch the agitator on.

4. Slowly pump the concrete into the delivery line. The process ofstarting to pump with thin concrete is completed when the twosponge balls and a solid concrete stream exit from the end hose.

NoteYou must begin pumping with a priming agent if the delivery lines arenew, or if the delivery line has not been used for a long time. Thispriming agent could be either a cement-water mixture (grout) or aspecially designed agent such as the “Putz Pack Primer.”

Commence pumping concrete by performing the following steps:

1. Mix the concrete vigorously in the truck mixer at maximum speed.Ensure that the concrete mix is uniformly prepared. Correct mixingof the concrete influences pumping performance.

2. Add concrete additives (deflocculants, set retarding admixtures) andmix for at least a further four minutes.

3. Pour the concrete from the truck mixer, silo, etc. into the agitatorhopper.

4. Switch the agitator on.

5. Begin delivery.

5.7.3 Starting Pumping

5.7.4 Pumping

Operation

A820062_05_0208D 5–45

NoteStart with a low output and increase this continuously after severalcubic yards (meters).

You should avoid breaks in pumping as far as possible, as the concretein the delivery line can start to set, or can become segregated due to thevibrations of the machine. Note the following points if breaks areunavoidable:-- Never leave the delivery line under pressure;-- Relieve the delivery line during short breaks in delivery by reversepumping briefly (2--3 strokes). Move the concrete at short intervalsby forward and reverse pumping;

-- You should avoid breaks when pumping concrete with a high slump(i.e., concrete that has a tendency to separate the grout from theaggregate) as the vibrations can segregate the concrete; When yourestart pumping, you must leave the pump switched to reversepumping until the transfer tube switches across fully on both sides.Only then can you switch over to forwards pumping again.

-- Pump the concrete back into the agitator hopper before long breaksin pumping. You must mix the concrete again before yourecommence pumping.

CautionNever use force to pump segregated concrete or concrete that hasbecome lumpy because it is beginning to set into the delivery line.Blockages can very easily be caused in this way.

The boom can sink during lengthy breaks in pumping as a result of thehydraulic fluid cooling. For this reason you must never leave the boomunattended in the extended position during breaks.

Breaks in Pumping

Operation

A820062_05_0208D5–46

Faults may occur even if you have observed all the notes on correctpumping. This section lists the faults occurring most frequently, andindicates how to rectify them.

11000601

1 2

3

1 Wedged aggregate2 Cement paste3 Boundary layer

The following faults can lead to blockages:-- delivery line insufficiently wetted;-- transfer tube leaking;-- lines leaking;-- concrete leavings in the transfer tube and delivery pipes;-- unfavorable concrete composition;-- segregated concrete;-- set concrete.

CautionIn the event of blockages, pump the concrete immediately back into theagitator hopper and mix it up. You can switch over to forwardspumping when the delivery cylinders and the transfer tube areswitching over automatically again without problem. Begin pumpingagain with care.

5.7.5 Possible Faults

Blockages

Operation

A820062_05_0208D 5–47

Continuous operation under high loading can lead to overheating of thehydraulic fluid. All pumps have a thermo--electrical cut--out. The pumpis automatically shut down if the fluid heats up to over 90 _C. Proceedas follows to prevent this:

1. Check that the hydraulic fluid radiator is operating correctly. If not,you can switch it on using the toggle switch on the control cabinet.

2. Reduce the output.

3. As shown in the diagram below, fill the water box with fresh wateras soon as the fluid temperature rises above 80_C.

Cooling -- Water box is shown with grate removed for illustration purposes only.Grate should not be removed unless a qualified mechanic is performing anapproved maintenance procedure.

4. Change the water continuously if the temperature continues to rise.

5. Look for the cause of fluid overheating and rectify it.

6. As shown in the diagram below, if you absolutely must supplyadditional cooling, direct the water jet onto the drive cylinders andthe piston rods of the drive cylinders.

Additional Cooling

CautionNever spray water on the hydraulic fluid reservoir because damagemay be caused to the hydraulic pump. Also never use sea water orwater containing salt for cooling because this will destroy the chromelayer on the delivery piston rods and delivery cylinders.

Overheating

Operation

A820062_05_0208D5–48

If the pump was switched off because of overheating, restart the pumpby performing the following steps:

1. Switch the pump off.

2. Never switch the engine off, as the hydraulic fluid radiator mustremain in operation.

3. Refresh the water in the water box.

4. Wait until the hydraulic fluid has cooled if you are not able to findthe fault immediately.

5. Once the red indicator lamp has extinguished, switch the pump backon and continue pumping slowly at reduced output.

6. Determine the cause of the fluid overheating once pumpingoperations have been completed and rectify the fault.

Restarting AfterOverheating

Operation

A820062_05_0208D 5–49

On some construction sites, it may be the case that the net reach of theboom is not adequate. You then have the option of connecting acontinuation delivery line to the boom tip or, if your machine isequipped with a lateral outlet, connecting a delivery line there.

Connect Continuation Delivery Line

CautionNo forces must be transferred from the fixed delivery line to the boomor vice versa.

The stationary delivery line may not place additional loading on theboom. This will jeopardize the stability of the machine.

The delivery hose should not be bent or stretched. Blockages can occurif it is bent. If it is stretched out, forces may be transmitted which canlead to damage to the structure, delivery hose or boom.

The boom can sink during pumping operations and place the deliveryhose under tension as a consequence of cooling of the hydraulic fluidin the boom cylinders. This can cause forces to be transferred or thedelivery hose to tear. You should therefore keep the delivery hose underconstant observation.

1. Extend the boom to bring the last arm approximately 4.9--6.6 ft(1.5--2 m) from the stationary delivery line.

2. Dismantle the end hose.

3. Mount a 9.8 ft (3 m) long delivery hose in place of the end hose.

4. Connect the delivery hose and the fixed delivery line using a SKHattachment coupling. Use an A seal as the seal.

5. Fasten the SKH attachment coupling securely to the structure.

5.7.6 Special Cases

ContinuationDelivery Line

Operation

A820062_05_0208D5–50

Prior to cleaning the concrete pump, perform the following steps:

NoteConcrete leavings that are deposited inside the delivery line or transfertube can cause damage and will reduce the cross-section as theyaccumulate. A clean delivery line and transfer tube is thereforeindispensable if you wish to be able to start pumping without problemson the next job. When cleaning, adhere to the following instructions:– Concrete leavings deposited around the wear ring can impair itsfunction. For this reason, thorough flushing of the wear ring isrequired at the end of a job, unless the next pumping job followswithin 30 minutes.

– Only use cold water at a maximum water pressure of 5 bar (73.5 psi)for cleaning all painted surfaces in the first four weeks of using themachine. Do not use any aggressive cleaning agents. The paint isnot fully cured until after this period and you will then be able to usesteam jet equipment or other devices.

– Never use sea water or other water containing salt for cleaningpurposes. You must rinse off any sea water that gets on the machine.

– Lock the remote control units away in the driver’s cab duringcleaning operations. The remote control units do not have awatertight casing. Execute the machine functions required duringcleaning operations from the control cabinet.

DangerLeave the hopper grate closed during all cleaning operations, sinceyou could be trapped by the agitator.

10800500

Do not reach into the hopper.

5.8 Cleaning

5.8.1 Preparations forCleaning

Operation

A820062_05_0208D 5–51

1. Find an appropriate use for the leavings to help in environmentalprotection.

Environmental protectionThe leavings should be used on the construction site. The leavingsshould be used as building rubble or be recycled if this is not possible:– We recommend that you use the Putzmeister “Leavings sheet” toallow you to make use of the concrete leavings. You can lay thisdown under the hopper before opening the hopper flap. The concretethen flows out into the sheet and can be transported to the site ofconcrete placement using a site crane.

– If the concrete is not to be used, you should bend a length ofreinforcing steel into a hook and insert it in the concrete. Once theconcrete has cured, you can transport the lump of concrete awayusing a site crane.

2. Ensure that you have a sufficient numbers of sponge balls and othercleaning accessories to clean the machine properly.

1

2

3

4

Sponge Balls and Other Accessories

1 Sponge pig2 Sponge cube3 Sponge ball4 Wash-out pig

Operation

A820062_05_0208D5–52

3. As shown in the diagram below, use the catch basket if you wish toforce the concrete out of the end of the pipe using water pressure orcompressed air. It must be designed such that the concrete can flowout unhindered, but that the sponge ball (cube, pig) is trapped andthat this simultaneously seals off the delivery line.

31201501

1

2

3

4

Catch Basket

1 Coupling2 Catch basket (closed pipe section)3 Spring pin (on both sides)4 Catch bracket

DangerRemember that:– The use of the catch basket is recommended when water is used toforce out the concrete, to ensure that the delivery line is sealed off,and no water can escape.

– A catch basket on the end of the delivery line is an absoluterequirement if you are forcing the concrete out using compressedair, as otherwise there is a risk of injury from the wash-out spongeand concrete as they are expelled.

– There is an increased risk of accident when cleaning withcompressed air. The cleaning operation must only be carried out bya subject expert or under his supervision. Putzmeister accepts noliability for damage caused by incorrect implementation ofcompressed air cleaning. All persons participating in the cleaningoperation must be instructed in the safety regulations.

Operation

A820062_05_0208D 5–53

4. As shown in the diagram below, use the wash-out adaptor when themachine is cleaned using water under pressure or compressed air.

4

3 2 1

Wash-Out Adapter

1 Connection for water or compressed air2 Isolating valve for connection3 Pressure dump bend4 Pressure dump cock

Operation

A820062_05_0208D5–54

5. If you wish to use cement bags for high pressure water cleaning,perform the following steps:

A. As shown in the diagram below, roll up 1 -- 2 empty cementbags together.

B. Immerse the rolled--up cement bags in water for about5 minutes before starting the cleaning operation.

Rolled--up Cement Bags

NoteCement bags soaked in water and rolled up have proved useful whencleaning the delivery line using water under pressure. The cement bagsprevent the washing water penetrating the concrete, flushing theconcrete out and causing blockages.

NoteYou may also prepare a short pipe section containing the cement bagsand a wash--out sponge before you start the cleaning operation.

Operation

A820062_05_0208D 5–55

6. Prior to cleaning the wear ring and seal ring on the transfer tube, thewater hose must be marked to ensure that the hose does not get cutby the switching transfer tube during cleaning. Mark the water hoseby performing these steps (refer to diagram below):

A. Measure the hose length required on the outside of the transfertube. The nozzle on the hose should be located shortly beforethe seal ring so that concrete leavings are washed away fromthe area around the wear ring and seal ring when the nozzle isset to spray.

B. Mark the measured length on the hose with adhesive tape, orsimilar.

NoteThe best way to clean the wear ring and seal ring on the transfer tubeis to rinse this area with water for some time from close up.

DangerThe machine must be switched off and the hydraulic system, includingthe accumulator, fully depressurized when you are measuring the hoselength required, as otherwise there is a risk of injury as the transfertube switches over.

1

Marking the Water Hose

1 Adhesive tape marking

Operation

A820062_05_0208D5–56

There are a number of options for cleaning a delivery line. Some of thefactors affecting which cleaning method you use include how theconcrete pump has been used and what equipment you have available.

On the next page, you will find a summary of delivery line cleaningmethods. The symbols used in the summary are explained below:

The delivery line is connected to the concrete pump.The leavings are pumped by the concrete pump out ofthe hopper and onwards to the site of concrete place-ment. Cleaning is from the hopper onwards to the site ofconcrete placement.

The delivery line is connected to the concrete pump.The leavings are sucked back by the concrete pumpfrom the site of concrete placement into the hopper.Cleaning is backwards from the site of concrete place-ment to the hopper.

The delivery line has been disconnected from theconcrete pump. The leavings are forced forwards fromthe start of the delivery line to the site of concrete place-ment using an external force (compressed air or waterunder pressure). Cleaning is from the start of the deliv-ery line to the site of concrete placement.

The delivery line has been disconnected from theconcrete pump. The leavings are forced backwards fromthe the site of concrete placement to the start of the de-livery line to using an external force (compressed air orwater under pressure). Cleaning is from backwards fromthe site of concrete placement to the start of the deliveryline.

Recommended method of cleaning

Method of cleaning not recommended

Prohibited method of cleaning

Method of cleaning not possible

5.8.2 Delivery LineCleaning Methods

Explanation of Symbols

Operation

A820062_05_0208D 5–57

Summary of Delivery Line Cleaning Methods

Delivery line

Leavingsfrom

to

Method ofcleaning

no onwards de-Compressed air only with

special

mp line livery line con-

nected to the Water under pressurespecialequipment

epump

liveryl

boom tipSuction cleaning

oncrete

omdeli

with onwardsCompressed air only with

special

ntedcon

Boom with onwards

delivery lineconnected to the

Water under pressurespecialequipment

mount

connected to theboom tip Suction cleaning

Truck--m

Compressed air

Tr

Lateral outlet Water under pressure

Suction cleaning

e

Compressed air only withspecial

ryline

Riser Water under pressurespecialequipment

delivery

Suction cleaning

naryde

Compressed air only withspecial

Station

Downpipe Water under pressurespecialequipment

S

Suction cleaning

Operation

A820062_05_0208D5–58

To clean the delivery line using the “suction cleaning” method, performthe following steps:

NoteSuction cleaning is the simplest and least hazardous method ofcleaning the delivery line.

1. Pump the agitator hopper out until the concrete is at the level of thetop of the delivery cylinder tubes. Then switch the pump off.

2. As shown in the diagram below, insert a water--soaked wash--outsponge (cube) into the end hose outlet:

Inserting a Water-Soaked Wash-Out Sponge

3. As shown in the diagram below, shift the placing boom into auniformly rising position. This makes it easier to pump theconcrete back as the concrete flows back under its own weight.

Shifting the Placing Boom into a Uniformly Rising Position

5.8.3 Delivery Line SuctionCleaning

Operation

A820062_05_0208D 5–59

4. Switch the pump to reverse pumping and then turn the pump on.This will cause the concrete and wash-out sponge to be pumpedback through the delivery line.

5. As shown in the diagram below, tap on the delivery line with apiece of hardwood (hammer handle) just ahead of the cleaning eyeduring the washing out process.

NoteTapping produces deep dull noises when there is concrete in thedelivery line. Tapping will yield high, clear sounds as soon as theconcrete and wash--out sponge have passed the point at which you aretapping. Use only a hammer handle to tap on the delivery line, asotherwise the pipe may be damaged.

20006203

Checking for theWash-Out Sponge by Tapping on the Delivery Line with HammerHandle

6. Switch the pump off as soon as the wash-out sponge has passed thepoint at which you are tapping.

Operation

A820062_05_0208D5–60

7. Open the wash--out port on the transfer tube, turn the wash-out portlid around and close it again with the pin pointing inwards.

Trapping the Wash-Out Sponge By Turning the Wash-Out Port Lid Around

8. Switch the pump back over to reverse pumping. The wash--outsponge will be trapped on the pin of the wash--out port lid. Thenswitch the pump off.

9. Open the wash--out port lid and remove the wash--out sponge.

10. Repeat the washing out procedure, as a single reverse pumping passof a wash--out sponge is not sufficient.

Operation

A820062_05_0208D 5–61

To clean the hopper, delivery cylinder and S-tube, perform thefollowing steps:

DangerIn no event should you insert the water hose, the spray gun or otherobjects through the grill into the hopper to spray out the deliverycylinders. Such objects may be trapped by the transfer tube as itswitches over and become damaged. The objects may be caused to flyabout, thereby causing an injury to you or other persons.

1. Drain off the leavings onto a sheet beneath the hopper byperforming the following steps (refer to diagram below):

A. Place the Putzmeister leavings sheet beneath the hopper.

B. Open the hopper flap beneath the hopper and let the leavingsflow out of the hopper.

C. Switch the pump over to reverse pumping. This pumps theleavings out of the delivery cylinders into the hopper and thusout of the hopper opening.

Draining Off the Leavings Onto a Sheet Beneath the Hopper

5.8.4 Cleaning the Hopper,Delivery Cylinder,and S-Tube

Operation

A820062_05_0208D5–62

2. Hoist away the concrete in the Putzmeister leavings sheet.

30000500

Hoisting the Concrete Away

CautionYou may only hoist a maximum of 0.5 m3 (.65 yd3)concrete(approximately 1200 kg or 2643 lbs) using the Putzmeister leavingssheet.

Operation

A820062_05_0208D 5–63

3. As shown in the diagram below, spray out the S-tube and deliverycylinder by performing the following steps:

A. Open the hinged elbow.

B. Allow the concrete pump to run slowly in reverse.

C. Spray the S-tube out carefully downwards from the hingedelbow. Slowly insert the hose up to the marking as you do this(mark the water hose using the procedure on page 5-39).

Spray Out the S-Tube and Delivery Cylinder with the Concrete Pump RunningSlowly in Reverse

D. Hold the water hose in this position, introduced as far as themarking, for several minutes, until only clean water runs out.This will flush out the two delivery cylinders alternately.

Insert the Water Hose into the Transfer Tube as Far as the Marking

4. Carefully spray out the hopper using a hose.

5. Hose down all components that have come into contact withconcrete.

Operation

A820062_05_0208D5–64

Once the delivery line, hopper, delivery cylinders and transfer tubehave been washed out, you must then rinse down thoroughly all partsof the machine that have come into contact with concrete. Concretethat is not washed off immediately can attack the paint, especially ifaggressive concrete additives have been used. Perform trucksuperstructure and post-washing operations by completing thefollowing steps:

CautionThe delivery line, water box, water tank and water pump must bedrained fully if there is a risk of freezing. The water box must also bedrained at normal temperatures during longer breaks in pumping, e.g.overnight and at weekends, etc. Leave the water outlet openafterwards.

Danger of explosionAtomized preserving agents are highly explosive. Keep away from allsources of ignition while spraying.

Danger of poisoningCleaning agents, solvents or preserving agents sprayed in air can enterthe lungs and cause serious health damage. You should, therefore, al-ways wear respiratory protection during this work.

1. Clean all seals and the seal seats. Grease the seals before replacingthem.

2. Clean the remaining parts of the machine by rinsing down with awater hose. Then spray the metal components with an anticorrosionagent or release agent.

3. Clean and drain the water box daily.

5.8.5 Truck superstructureand Post-WashingOperations

Operation

A820062_05_0208D 5–65

To teardown the machine after a concrete pour and prepare it for travel,perform the following steps:

5.9.1 Boom TeardownNoteWhen the arm assembly is folding, the end hose cannot automaticallydrop into the end hose catch brackets because of the design of the armassembly. Therefore, you must first move the arm into a position whichallows the end hose to drop into the end hose catch brackets.

CautionAlways observe the specified sequence for folding and unfolding theboom. Failure to comply with the sequence may allow the crank leverin the C hinge to compress the delivery line, adjacent hydrauliccylinders, or other components. Retract the placing boom carefully.

Danger

Arms 3 and 4 must not be moved behind the C hinge when unfolded orpartially unfolded during the entire boom operation. In this armposition, the rod side C cylinder hydraulic pressure is so high that thepressure limiting valve responds and the boom will gradually slump.

There is also a risk of uncontrolled boom movements.

Before moving arm 3 to the rear, you must move arm 4 towards arm 3until the boom tip is approximately 1 m from the C hinge.

5.9 Teardown

Operation

A820062_05_0208D5–66

1. As shown in the diagrams below, catch the end hose by performingthe following steps:

A. Retract arm 3 until it is vertical.

B. Unfold arm 4 completely in a single motion so that the endhose drops into the end hose catch brackets.

Operation

A820062_05_0208D 5–67

CautionYou must fold arm 3 in fully before you fold arm 4 in fully, otherwisethe C hinge crank lever will press on the boom tip pipe bend.Therefore, only fold arm 4 in fully once you have folded arm 3 in fully.

2. As shown below, fold arm 4 in so that the boom tip isapproximately 1 m from the C hinge.

3. As shown below, fold arm 3 in fully until it rests against arm 2.

Operation

A820062_05_0208D5–68

4. As shown below, fold arm 4 in fully until it rests against arm 3.

CautionTake care when folding arm 2 in that you do not damage the driver’scab or other elements. It may be necessary to raise arm 1 higher.

5. As shown below, lower the arm assembly onto the cradle byperforming the following steps:

A. Fold arm 2 in fully until it rests against arm 1.

B. Slew the arm assembly to the boom cradle and lower it intoposition.

Lowering the Arm Assembly Onto the Cradle

NoteThe arms must be fully folded and lie on the supports provided.Check that the end hose is secured for transport.

Operation

A820062_05_0208D 5–69

5.9.2 Outriggers Teardown

NoteThe same safety and operational rules apply for retracting theoutriggers as for extending them (refer to the “Outriggers Setup”section on page 5–23).

6. As shown in the diagram below, unlock the outrigger legs byperforming the following steps:

A. Pull out the spring pin (1).

B. Pull the lever on the snaplock upwards (2).

12100101

1

2

Outrigger snaplock -- Unlock the outrigger legs before you retract them or swingthem in.

7. On the radio or cable remote control, move the horn/outrigger/resetswitch to the outrigger position.

8. Raise and then retract (or swing in) the rear outriggers.

CautionOnly execute one outrigger at a time. Observe leveling bubble andensure that truck remains level as each outrigger is positioned.Stability is jeopardized at a deviation from horizontal of 3_ or more.

9. Repeat Step 8 for the front outriggers.

NoteThe snaplocks lock the support legs again automatically as soon asthey have reached their fully retracted position.

Operation

A820062_05_0208D5–70

10. On the radio or cable remote control, move the horn/outrigger/resetswitch to the center position.

11. Secure all the outrigger leg snaplocks with spring pins.

5.9.3 Controls Teardown

12. At radio remote control transmitter (or cable remote control),perform the following steps:

• Push in emergency stop button. This should depressurize thehydraulic system by dumping the accumulator.

• Turn power switch to “off” position (radio only).

13. If using a cable remote control, roll up cable and store cable.

14. Store radio remote control transmitter (or cable remote control) in aprotected location, preferably in the truck cab.

15. Switch the power take-off (PTO) off by performing the followingsteps:

CautionThe following points must be complied with to prevent damage whenusing power take-off gearboxes:– The transmission must be in neutral when the power take-offgearbox is switched on or off.

– If the engine was shut down during pumping operations and yourtruck has a manual transmission, you must depress the clutch beforestarting it up again.

A. If your vehicle has a manual transmission, perform these steps:• Push in clutch pedal (clutch disengaged).• Place truck transmission in neutral• Let clutch pedal out (clutch engaged).

B. If your vehicle has an automatic transmission, shift selectorfrom “D” (Drive) to”N” (Neutral).

C. Position concrete pump PTO switch (located on right side ofdriver’s seat) to “DRIVE” position (PTO disengaged).

D. Verify that green “PUMP” light goes out.

E. Release parking brake.

Operation

A820062_05_0208D 5–71

F. If your vehicle has an automatic transmission, shift selector to“D” (Drive). Display indicates “1” signifying that the trucktransmission is in 1st gear.

16. Secure the end hose and the accessories against falling from thetruck.

17. Confirm that the accumulator is depressurized by looking at theaccumulator pressure gauge.

Operation

A820062_05_0208D5–72

To pump concrete with the Emergency Stroke Kit (P/N 134931),perform the following steps:

DangerTHE EMERGENCY STROKE KIT SHOULD ONLY BE USED INAN EMERGENCY CONDITION. THE EMERGENCY STOP(E-STOP) BUTTON DOES NOT WORK WHEN USING THEEMERGENCY STROKE KIT.

1. Stop truck engine and verify that shift circuit pressure is at zero.

2. Disconnect pump harness from the following valves on the compact block:• Main control valve (2 connections)• Accumulator dump valve (1 connection)

3. Connect Emergency Stroke Kit wiring harness to three connections disconnected inStep 2 and battery (refer to diagram below):

OFF

ON

BatteryToggle Switch

MainControl

Accum.Dump

20 Amp Fuse

Emergency Stroke Kit (Connected Between Battery and Compact Block)

4. Start truck engine.

5. Ensure that truck engine RPM is greater than 900 RPM.

6. Use toggle switch on Emergency Stroke Kit wiring harness to shift drive cylinders atend of each stroke.

7. During an emergency condition or when job has been completed, stop truck engine.

5.10 Pumping Concretewith the EmergencyStroke Kit

A820062_06_0412 6–1

6 Maintenance

In this section you will find information on maintenance work which isnecessary for the safe and efficient operation of the machine.

Following the general maintenance information, you will find themaintenance cards necessary for this machine.

We would like to emphasize that all prescribed checks, inspections andpreventative maintenance work must be conscientiously carried out.Otherwise, we will refuse to accept any liability or to honor thewarranty. Should you ever be in any doubt, our After Sales Departmentis always ready to give you advice and assistance.


6.1 Maintenance Intervals 6–2

6.2 General Tightening Torques 6–4

6.3 Functional Fluids 6–7

6.4 Recommended Lubricants 6–10

6.5 WK00_001: Visual Checks 6–15

6.6 WK03_001: Changing the Hydraulic Fluid 6–17

6.7 WK03_002: Function Checks 6–23

6.8 WK03_006: Performing Maintenance on the Accumulator 6–25

6.9 WK04_001: Filter Change 6–31

6.10 WK04_002: Hoses 6–39

6.11 WK04_005: Vacuum Meter 6–43

6.12 WK06_009: Change of Delivery Piston with KEP 6–45

6.13 WK07_001: Lubricating the S Transfer Tube 6–55

NO TAG WK07_011:S Transfer Tube

NO TAG

6.14 WK10_007: Measuring the Wall Thickness 6–81

6.15 WK20_044: Lubricating the M 36Z Placing Boom 6–87

6.16 WK21_011: Lubricating the Boom Pedestal (TRDI 70) 6–89

6.17 WK25_001: Replacing the Delivery Line 6–91

Maintenance

A820062_06_04126–2

The following table shows the intervals for the various maintenancetasks. The associated maintenance cards can be found further on in thissection.

NoteHave the initial After Sales service after 100 hours of operation carriedout by a Putzmeister After Sales service engineer in accordance withthe enclosed inspection booklet. The machine operator responsible forthe machine should be present for this service.

Assembly Actionevery ... hours of operation otherAssembly Actiondaily 50 100 250 500 1000

otherintervals

Lubricate truck superstructure D weekly

Visual and function check on all safetyequipment

D

General Check threaded unions against torquetable

as required

Inspection by subject expert D annually

Visual inspection of electrical cabling D

Check hydraulic fluid level D

Drain off condensed water D

H dr lic s stem

Visual check of the lines(damage/leaks)

D

Hydraulic systemFull fluid change (after fluid analysis) D

Clean fluid sump D

Check hydraulic cylinder for tightness(visual inspection)

monthly

Check contamination indicator on thefilters

D

Fluid filter Replace boom filter element as required

Replace intake filter element as required

Water tank Check water level D

6.1 MaintenanceIntervals

Maintenance

A820062_06_0412 6–3

otherintervals

every ... hours of operationActionAssembly other

intervals100050025010050dailyActionAssembly

Full oil change splitter box D

Full oil change agitator gearbox D

Transmission Full oil change slewing geartransmission

D annually

Condensed water slewing gear trans-mission

D

Boom pedestal Check slewing ring bolts (if applicable) D

Wear check D

Transfer tube Check and adjust sealing gap D

Check tightening torque of bolts D

Deli er lineCoupling safety clips D

Delivery lineCheck wall thickness D

Delivery piston

Check threaded unions and securingwire

D

Delivery piston

Check wear on delivery pistons weekly

Parts in contact with concrete Wear check D

Centralized lubrication system Check grease level D

Check oil level D

CompressorFull oil change D

CompressorClean air intake filter D

Check threaded unions D

Universally jointed shafts(in normal operating conditions)

Lubricate D

Universally jointed shafts(in extreme operating conditions)

Lubricate D

Truck engineIn ccord nce ith the tr ck m n f ct rer’s m inten nce specific tions

Truck transmissionIn accordance with the truck manufacturer’s maintenance specifications

Maintenance

A820062_06_04126–4

Tightening torques depend on bolt grade, thread friction and bolt headbearing area. The values given in the following tables are for guidance.These values should only be used if no other values are specified in therelevant sections of the Operating Instructions or in spare parts sheets.

CautionYou must always use bolts of the same size and grade when you have toreplace bolts. Bolts with adhesive in the locking threads and self--lockingnuts must always be replaced after removal.

The tables below give the maximum tightening torques Md in Nm for afriction factor µtot. = 0.14, for a lightly--oiled or lightly--greased thread.

NoteAll tightening torques are multiplied by a factor of 1.1 for bolts withcement in the thread.

6.2 General TighteningTorques

Maintenance

A820062_06_0412 6–5

Set screws -- metric triangular thread DIN 13, Part 13Dimensions

[mm]Tightening torque

Md [Nm]Tightening torque

Md [Ft-Lb]M SW 8.8 10.9 12.9 8.8 10.9 12.9

M 4 7 3.0 4.4 5.1 2.22 3.26 3.77

M 5 8 5.9 8.7 10 4.37 6.44 7.4

M 6 10 10 15 18 7.4 11.1 13.3

M 8 13 25 36 43 18.5 26.6 31.8

M 10 17 49 72 84 36.3 53.3 62.2

M 12 19 85 125 145 62.9 92.5 107

M 14 22 135 200 235 99.9 148 174

M 16 24 210 310 365 155 229 270

10000900M 18 27 300 430 500 222 318 370

10000900

M 20 30 425 610 710 315 451 525

SW = Width across flatsG

M 22 32 580 820 960 429 607 710X.X = Grade 8.8, 10.9, 12.9 M 24 36 730 1050 1220 540 777 903

M 27 41 1100 1550 1800 814 1147 1332

M 30 46 1450 2100 2450 1073 1554 1813

Set screws -- metric precision thread DIN 13, Part 13Dimensions

[mm]Tightening torque

Md [Nm]Tightening torque

Md [Ft-Lb]M SW 8.8 10.9 12.9 8.8 10.9 12.9

M 8¢ 1 13 27 39 46 19.98 28.86 34.0

M 10¢ 1.25 17 52 76 90 38.48 56.24 66.6

M 12¢ 1.25 19 93 135 160 68.82 99.9 118.4

M 12¢ 1.5 19 89 130 155 65.86 96.2 114.7

M 14¢ 1.5 22 145 215 255 107.3 159.1 188.7

M 16¢ 1.5 24 225 330 390 166.5 244.2 288.6

M 18¢ 1.5 27 340 485 570 251.6 358.9 421.8

10000900M 20¢ 1.5 30 475 680 790 351.5 503.2 584.6

10000900M 22¢ 1.5 32 630 900 1050 466.2 666 777

SW = Width across flatsG

M 24¢ 2 36 800 1150 1350 592 851 999X.X = Grade 8.8, 10.9, 12.9 M 27¢ 2 41 1150 1650 1950 851 1221 1443

M 30¢ 2 46 1650 2350 2750 1221 1739 2035

Maintenance

A820062_06_04126–6

Every time the joint has been undone, the union nut must be tightenedsecurely, without the use of excessive force.

Flared screwed joints

Externaldiameter/Type

Md [Nm] Md[Ft--Lb]


Md [Nm] Md[Ft--Lb]

6 L 20 14.8 18 L 120 88.8

8 L 40 29.6 20 S 250 185

12L 55 40.7 25 S 400 296

12S 80 59.2 30 S 500 370

15 L 70 51.8 38 S 800 592

16 S 130 96.2

NoteHold threaded union spigot fast against turning with wrench.

10400100

Tightening flared screwed joint

Every time the joint has been undone, the union nut should be tightenedagain without excessive force to ensure that the joint is tight.

6.2.1 Flared ScrewedJoint, Reassembly

6.2.2 Profiled Ring Joint,Reassembly

Maintenance

A820062_06_0412 6–7

This section lists all the functional fluids used in your machine.

CautionNever use hydraulic fluids or lubricants with additives such asmolybdenum. Such additives can attack the bearings.

The hydraulic system is filled with:-- mineral hydraulic fluid (HV) or-- biologically degradable hydraulic fluid based on a synthetic ester(HEES) or

-- non--readily flammable hydraulic fluid (HFC).

Please see the machine card to find out what the initial filling was inyour machine.

DangerNever mix hydraulic fluids with different characteristics (i.e. do not mixbiologically degradable hydraulic fluid with mineral hydraulic fluidsetc.).

NotePlease only use a hydraulic fluid complying with the classification andrequirements standards specified in the lubricant recommendation fortopping up or a full fluid change. HEES synthetic esters and HFCaqueous solutions from different manufacturers must not be mixedtogether without prior approval from the manufacturers concerned.

When hydraulic fluids of different viscosity grades are mixed, the newviscosity is determined by the mix ratio. Loss of quality is possible ifhydraulic fluids from different manufacturers are mixed. For thisreason, you must always consult the manufacturer before mixing fluids.

When the hydraulic fluid is changed, some 10 -- 15% of the oldhydraulic fluid remains in the system (in cylinders, pumps, lines, etc).

Take note of VDMA’s changeover guidelines and manufacturer’sinstructions if you are changing over your fluid. Please contact themanufacturers concerned if you have any queries regarding thesuitability and miscibility of hydraulic fluids.

6.3 Functional Fluids

6.3.1 Hydraulic Fluid

Maintenance

A820062_06_04126–8

The power take--off and agitator gearboxes are filled with an API GL4transmission oil of viscosity grade SAE 90.

Use only high quality transmission oil matching this specification fortopping up or for a full oil change (observe the manufacturer’sinformation).

Use a multipurpose lithium soap base grease for lubrication.Marking in accordance with DIN 51 502: K2K--30, NLGI Class 2.

Fill the centralized lubrication system with a multipurpose lithium soapbase grease.Marking in accordance with DIN 51 502: K1K--30, NLGI Class 1.

We recommend grease marked K E 2G--60 in accordance withDIN 51502, NLGI Class 2 in a deviation from the lubricants table ifyou wish to use a low temperature grease in the centralized lubricationsystem under conditions of extreme cold.

The engine and the truck transmission are filled by the truckmanufacturer. Maintenance only in accordance with the truckmanufacturer’s specifications.

6.3.2 Oil for the PowerTake-Off (PTO),Rotor and AgitatorGearboxes

6.3.3 Manual Lubrication

6.3.4 CentralizedLubrication System

Low temperaturegreases

6.3.5 Truck Engine Oil andTransmission Oil

Maintenance

A820062_06_0412 6–9

Level of contaminant 18/14 in accordance with ISO 4406 is specified forlubrication and the hydraulic system. You can find the level ofcontaminant of the original filling from the report of results on themachine card.

Please consult the Putzmeister After Sales Department should youdiscover that the functioning of your machine is impaired with one ofthe lubricants or hydraulic fluids used. We will carry out a lubricantanalysis to determine the cause.

Do not store oils and greases in the open air. Water may be absorbedthrough the bung hole in the event of changes in the exposure to theweather.

Only store the barrels lying on their side and supported on timberblocks, with the bung hole facing upwards.

Environmental protectionYou must carefully collect all functional fluids, e.g. used oil (including bio-logically degradable oils), filters and auxiliary materials and dispose ofthem separately from other waste. You must keep used oils of varioustypes separate in order to keep disposal costs as low as possible.

Observe the national and regional regulations applicable to your area.Only work with waste disposal companies who are approved by theresponsible authorities.

6.3.6 Level of Contaminant

6.3.7 Lubricant Analysis

6.3.8 Storage ofLubricants

Maintenance

A820062_06_04126–10

We have listed the suitable lubricants in the tables on the next page.Putzmeister accepts no liability for the quality of the lubricants listed orfor changes in quality made by the lubricant producer without changingthe grade designation.

NotePlease use only Putzmeister hydraulic fluid, part no. 239879002, whenyou are topping up the hydraulic fluid or carrying out a full fluidchange if your machine was filled with non--readily flammable hy-draulic fluid in the works (HFC as specified in the 7th LuxembourgReport).

Please use only Putzmeister hydraulic fluid, part no. 239693000, whenyou are topping up the hydraulic fluid or carrying out a full fluidchange if your machine was filled with a synthetic ester in the works.

Putzmeister accepts no liability for damages caused by mixing fluidsfrom different manufacturers.

You must first consult Putzmeister Department APS if you wish to usehydraulic fluids with viscosity grades other than Multi-grade 68 (e.g.,at higher ambient temperatures).

The proportion of residual fluid must not be greater than 2% after afluid change from HV to HEES. This means that a flushing filling withthe full quantity of the new hydraulic fluid must be carried out. In addi-tion, for reasons of gasket compatibility, a fluid change must be carriedout no later than 6 months after the machine is commissioned. It shouldalso be noted, at this point, that all filters must be changed after 50hours of operation, since deposits may be dissolved and transported tothe filters by the new fluid.

6.4 RecommendedLubricants

Maintenance

A820062_06_0412 6–11

CautionThe following points must be complied with in order to preventdamage:– You must warm the machine up briefly if you wish to start using itwhen the hydraulic fluid temperature is below 0 _C. To do this, en-gage the power take--off, switch off the concrete pump and allow themachine to idle for a few minutes.

– The machine should not be placed under full load until the tempera-ture of the hydraulic fluid (Multi-grade 68) has risen above 10 _C.

– The ideal temperature for the hydraulic fluid (HV or HEES,Multi-grade 68) is between 40 _C and 70 _C.

DangerNever mix hydraulic fluids of different types, ie do not mix biologicallydegradable hydraulic fluids with mineral hydraulic fluids etc.

Maintenance

A820062_06_04126–12

6.4.1 Hydraulic Fluids

Type Petroleum Synthetic ester Aqueous solutions

Class HEES HFC

ClassificationDIN 51502ISO 6743/4

RequirementDIN 51524 Part 3 — —

ISO 6743 Part 4 — —

VDMA 24318 24568 24317 / 24320

Other — — 7th Luxembourg ReportViscosities

DIN 51519

ISO 3448

mm2/s ISO VG 68 46 46

Use30_F to 210_F

(-10_C to +90_C)15 _F to 90_F

(-10_C to +90_C)--4_F to 140_F

(--20_C to +60_C)Particular char-acteristics

Multi-grade biodegrades quickly non--readily flammable

Initial fillingPart number A026533 239693.000 239879.002

Manufacturer Benz OilBECHEMHYDROSTAR

HEP 46FUCHS HYDROTHERM

46 MChangeover guidelines

VDMA — 24569 24314

6.4.2 Oils and Greases

Engine oil Transmission oil*Greasing(manual)

Centralizedlubricationsystem

Marking in acc.with DIN 51 502

HD HYP K2K--30 K1K--30

Requirementsstandard

API CH--4/SJ API GL4 DIN 51 825 DIN 51 825

Characteristics mineral mineral, lithium soap

Maintenance

A820062_06_0412 6–13

Viscosity grade,NLGI Class

SAE 15W--40DIN 51511

SAE 90DIN 51512Standard

SAE 80DIN 51512Winter

NLGI Class 2DIN 51818

NLGI Class 1DIN 51818

Part number 000173.005 000101.006 — A026511 360001.008* The transmission oil for rotor pumps is listed separately.

Maintenance

A820062_06_04126–14

00--001Page 1 of 2

Maintenance Card

6–15WK00_001_9411GB

This maintenance card describes visual checks that you must carry outbefore commencing any maintenance work. You will find the serviceintervals in the maintenance summary at the start of this chapter.

Refer also to the maintenance cards:Filter changeHoses

No special tools required.

DangerInspect the electrical cables particularly closely and carefully. There isa danger of overvoltages from defective cables, particularly when thereis high air or ambient humidity. There is a danger of fire and explosionthrough the formation of sparks when the machine is used in apotentially explosive atmosphere.

6.5 Visual Checks

00--001Page 2 of 2

Maintenance Card

6–16 WK00_001_9411GB

The general visual inspections listed below should always be carriedout before any maintenance work, and also each time before startingwork with the machine.

" Check the fill levels of the functional fluids.

" Check that all safety equipment is available and in a fully func-tioning condition.

You must have any damage found in the electrical system rectifiedimmediately by a qualified electrician.

" Check that all electrical connections are secure and free fromcorrosion.

" Check that the electrical cables have no breaks.

" Check the insulation on the electrical cables.

Timely detection and rectification of damage to the hydraulic systemcan prevent lengthy downtimes and high repair costs.

" Check that the displays on the vacuum meter of the suction fil-ters are still in the green range. The vacuum filters must be re-placed if the displays are in the red range.

Maintenance card: Filter change

" Check the contamination indicators on the boom filters. The fil-ters are in order if the red button remains depressed. The filtermust be replaced if the red button pops out.


" Check the oil cooler for contamination and deposits.

" Check all hydraulic hoses for leaks.

Maintenance card: Hoses

" Check all hydraulic threaded unions for tightness and leaks.


General

Electrical system

Hydraulic system

01−019Page 1 of 6

Maintenance card

��1wk01_019_0807en

This maintenance card describes changing the oil and checking the

oil level in the transfer gearbox.

No further maintenance cards required.


CautionThe transfer gearbox must never be shifted when under load. Only

shift the transfer gearbox when the Cardan shaft is stationary.

Check that the expirator screws are clean and operating correctly

each time that the oil in the transfer gearbox is changed. If necessary,

clean or replace the expirator screws.

The transfer gearbox must never be operated if an expirator screw is

missing or defective. Otherwise, leaks may occur due to an increase

in pressure.

This may then cause damage to the transfer gearbox.

NoteThe transfer gearbox lubrication circuit is divided into the following

areas:

– Oil circuit �A" lubricates the gearbox.

– Oil circuit �B" lubricates the connection of the hydraulic pumps.

Check the oil level in oil circuit �B" each time the oil is changed in the

transfer gearbox and top up with gearbox oil, if necessary. It is not

necessary to change the oil in oil circuit �B".

01-019 G64 C transfer gearbox

Maintenance card01−019Page 2 of 6

��2 wk01_019_0807en

This section describes how to change the transfer gearbox oil in oil

circuit �A".

NoteThe oil change intervals can be found in the maintenance summary

at the start of this chapter.

Information concerning oil specification and filling capacity is con−

tained in the spare parts sheet. It is not permissible to use oils other

than those specified without first consulting with Putzmeister after−

sales service (APS department).

Information concerning parts required and tightening torques can be

found in the spare parts sheet.

Environmental protection

All functional fluids and operating materials, e.g. oils (including bio−

logically degradable oils), filters and auxiliary materials must be

carefully collected and disposed of separately, both from each other

and from other waste. Different categories of oil must also be kept

separately from each other. Nationally and regionally applicable

disposal regulations must be observed for these materials.

NoteBefore changing the oil, carry out the following procedures:

– Engage the power take−off and allow the transfer gearbox to

warm up.

– Disengage the power take−off.

– Allow the oil to settle for a while, then start the oil change.

Oil change in oil circuit “A”

01−019Page 3 of 6

Maintenance card

��3wk01_019_0807en

The gearbox oil can be added via the bore hole of expirator

screw �A" (1). The oil level in the gearbox must reach as far as

oil level check screw �A" (2).

wk01_019_0807en 1

OIL1

2

3

No. 0 Designation

1 Expirator screw �A"

2 Oil level check screw �A"

3 Oil drain plug

� Unscrew expirator screw �A" (1) and oil level check screw �A" (2).

In the process, make sure that no foreign matter enters the

gearbox through the open bore holes.

� Drain the gearbox oil via the bore hole of the oil drain plug (3).

� Clean all screws/plugs that were removed.

� After the oil has drained, replace the sealing ring of the oil

drain plug (3) and screw the plug back into place using the

specified tightening torque.


��4 wk01_019_0807en

� Add the gearbox oil via the bore hole of expirator screw �A" (1).

The oil level must reach as far as the bore hole of oil level

check screw �A" (2).

� After approx. 10 minutes, check the oil level and correct,

if necessary.

� Replace the sealing rings of expirator screw �A" (1) and oil

level check screw �A" (2) and refit these screws using the

specified tightening torques.

This section describes how to check the transfer gearbox oil level in

oil circuit �B". The oil level in the oil chamber must reach as far as oil

level check screw �B" (5). The gearbox oil can be added via the bore

hole of expirator screw �B" (4).

wk01_019_0807en 2

OIL4

5

No. 0 Designation

4 Expirator screw �B"

5 Oil level check screw �B"

Checking the oil levelin oil circuit “B”

01−019Page 5 of 6

Maintenance card

��5wk01_019_0807en

� Unscrew expirator screw �B" (4) and oil level check screw �B" (5).

In the process, make sure that no foreign matter enters the

gearbox through the open bore holes.

� Clean all screws/plugs that were removed.

� Check the oil level in the oil chamber. The oil level must reach

as far as the bore hole of oil level check screw �B� (5).

� If required, add the gearbox oil via the bore hole of expirator

screw �B" (4).

� Replace the sealing rings of expirator screw �B" (4) and oil

level check screw �B" (5) and refit these screws using the

specified tightening torques.


��6 wk01_019_0807en

03--001Page 1 of 6

Maintenance Card

6–17WK03_001_9909

This maintenance card describes how to carry out a full oil change onthe hydraulic system. You will find the service intervals in themaintenance summary at the start of this section.

Refer also to the maintenance cards:Function checksFilter changeHoses


NoteCleanliness is of the greatest possible importance in the maintenanceof hydraulic systems. You must make it impossible for dirt or otherimpurities to enter the system. Even small particles may cause valves tobe scored, pumps to seize and choke and control bores to becomeblocked.

Hydraulic fluid drums must stand for some time before the fluid istaken from them. Never roll the barrels to where you will be drawingoff the fluid. Clean bungs, filler caps and their surroundings beforeopening them.

If possible, you should use a filler unit to fill up the hydraulic system.Never leave the tank lid open longer than necessary.

6.6 Changing theHydraulic Fluid

03--001Page 2 of 6

Maintenance Card

6–18 WK03_001_9909

The following tasks must be carried out before starting the full fluidchange:

" Switch off the remote control.

" Switch the hydraulic pumps off.

" Reduce fluid pressure completely.

" Check the contamination indicator on the vent filter of the fluidreservoir. You must replace the filter element for the vent filterwhen the red check ring is visible in the inspection glass.


10401903

1

1 Red check ring in the inspection glass

Preparation

03--001Page 3 of 6

Maintenance Card

6–19WK03_001_9909

DangerThe accumulator pressure in pressurized systems must be released.Confirm via gauge.

" Switch the drive engine off.

" Secure the system against unauthorized starting – if you haveany keyed switches, remove the key and disconnect the supplyvoltage.

" Secure your working area and fix notices to the blocked controlsand setting devices.

10300400

Draining off the fluid

Environmental protectionYou must make sure you collect the old hydraulic fluid and dispose of itin accordance with the regulations. Biologically degradable hydraulicfluids must also be disposed of separately from other waste, just likemineral hydraulic fluids!

" Remove a hose from the hydraulic system tank and drain off thefluid.

Changing the fluid

03--001Page 4 of 6

Maintenance Card

6–20 WK03_001_9909

" Then disconnect all hoses from the tank.

NoteMark the hoses and their connection points for re--assembly.

10400300

Marking the hoses

" Wipe out all the openings with a lint--free cloth. Wipe as far intothe tank as possible when doing this. You should also rememberthat there may also be separate apertures intended for tank clean-ing.

" Remove all filter inserts.


" Change all filters and refit the filter elements.

" Replace any defective hoses.


Environmental protectionDispose of the old filter inserts in accordance with the regulations inforce.

03--001Page 5 of 6

Maintenance Card

6–21WK03_001_9909

10300500

Filling the tank

" Fill the tank with new fluid.

NoteOnly fill the tank through the mesh in the filler inlet. Fill up the tank upto the “Maximum” marking after bleeding and a test run. Use only thehydraulic fluids specified in the lubrication recommendations.

" Remove the dirt deposits from the oil cooler.

" Check all screwed joints and tighten where necessary. Check allflared screwed joints.


" Check the electrical connections.

" Carry out all function checks.

Maintenance card: Function checks

" Bleed hydraulic system.

" Carry out several test runs.

" Refit all the safety equipment, markings and notices you haveremoved.

03--001Page 6 of 6

Maintenance Card

6–22 WK03_001_9909

03--002Page 1 of 2

Maintenance Card

6–23WK03_002_9411GB

This maintenance card describes the inspection of machine functions.The inspections are carried out with the machine running. You will findthe service intervals in the maintenance summary at the start of thischapter.


The following special tools are required:Pressure gauge and connections for the tapping points shown in thehydraulic circuit diagram

NoteOnly qualified personnel authorized by us may carry out work on thehydraulic system. Notify the Putzmeister After Sales department or thedealer/agent who looks after you immediately should you find anyirregularities.

" Measure the pressures generated by the pumps, using the mea-suring equipment specified directly on the pumps, and compareyour results with the values specified in the Measurements sheet.

" Check the proper functioning of the pressure--relief valves in thehigh pressure circuit and the pressure accumulator.

6.7 Function Checks

03--002Page 2 of 2

Maintenance Card

6–24 WK03_002_9411GB

03--006Page 1 of 6

Maintenance Card

6–25WK03_006_9909

This maintenance card describes how to check the accumulatorpre--charge pressure. You should also take notice of any requirementsvalid in the country of use or specified by the operator.


The following special tools are required:

– Charging and Gauging Kit (Putzmeister #311803)– Gas Valve Core Tool– Spanner Wrenches– Bladder Pull Rod– Sockets -- 27 mm, 36 mm– Blunt Flathead Screwdriver– Soft Faced Hammer– Torque Wrenches

5

2

1

3

4

Charging and Gauging Kit

1 T-handle2 Manual bleed valve3 Check valve4 Cap nut5 Charging hose, including cap screw connections

6.8 PerformingMaintenance on theAccumulator

03--006Page 2 of 6

Maintenance Card

6–26 WK03_006_9909

Danger of explosionUSE ONLY DRY NITROGEN TO FILL THE ACCUMULATOR.THERE IS A DANGER OF EXPLOSION IF COMPRESSED AIR,OXYGEN OR OTHER GASES ARE USED.

NoteCheck the accumulator pre--charge pressure once the hydraulic fluidhas warmed up to its operating temperature of 122_F (50 _C) to158_F (70 _C).

The setpoint value for the accumulator pre--charge pressure may befound on the hydraulic schematic (item 120). The actual value youmeasure may not be more than 15% less than the setpoint valuespecified.

WarningAdhere to the following safety regulations when performingmaintenance on the accumulator:– The hydraulic accumulator is a pressurized vessel and only qualifiedtechnicians should perform the necessary repairs.

– The fluid must always be drained completely from the accumulatorbefore performing any work.

03--006Page 3 of 6

Maintenance Card

6–27WK03_006_9909

1

2

10

11

12

6

7

8

5

6

7

8

9

14

1516

10

11

12

133

4

Accumulator

1 Gas valve core2 Lock nut3 Shell4 Bladder5 Anti-extrusion ring6 Flat ring7 O--ring8 Spacer ring9 Locknut10 Valve protection cap11 Valve seal cap12 O--ring13 Name plate14 Fluid port15 Vent screw16 Seal ring

03--006Page 4 of 6

Maintenance Card

6–28 WK03_006_9909

To check accumulator pre-charge pressure, perform the followingsteps:

NoteThe proper gas pre--charge pressure (1320 PSI or 90 bar) is set at thefactory. It is suggested that the pressure be rechecked approximately3--4 months after placing unit in service and every 12 monthsthereafter.

DangerBEFORE CHECKING THE PRE-CHARGE PRESSURE, BESURE MACHINE IS SHUT DOWN AND ALL HYDRAULICPRESSURE AND FLUID IN ACCUMULATOR HAS BEENRELIEVED.

1. Unscrew valve protection cap (#10) and valve seal hex cap (#11).Be careful not to damage O--ring (#12) when removing cap.

2. To connect gauging unit to accumulator, perform the followingsteps:• Turn T-handle counterclockwise until resistance is felt.• Close manual bleed valve, hand tight.• Connect gauging unit to accumulator by screwing cap nut onto

gas valve, hand tight.

3. After gauging unit has been installed, turn T-handle clockwise amaximum of 3 full turns from full counterclockwise position.

4. If gauge does not indicate 1320 PSI (90 bar), perform appropriateprocedure to increase or decrease accumulator pressure:

If pressure reading is . . . Then . . . By performing this procedure . . .< 1320 PSI (90 bar) Increase pressure Increasing Accumulator Pressure> 1320 PSI (90 bar) Decrease pressure Decreasing Accumulator Pressure

5. If gauge indicates proper pre-charge pressure, remove charging andgauging unit by performing the following steps:• Turn T--handle counterclockwise until resistance is felt to close

gas valve.• Open manual bleed valve to relieve pressure in gauging unit.• Disconnect gauging unit by unscrewing cap from gas valve.• Re-install valve seal hex cap and tighten to 20 lb. ft. (27 Nm).• Re-install valve protection cap, hand tight.

6.8.1 CheckingAccumulatorPre-Charge Pressure

03--006Page 5 of 6

Maintenance Card

6–29WK03_006_9909

To decrease pressure in accumulator, perform the following steps:

1. Install charging and gauging unit as per Steps 1--3 of “CheckingAccumulator Pre-Charge Pressure” procedure on page 6–28.

2. Carefully open manual bleed valve, allowing gas pre--chargepressure to release slowly.

3. Monitor gauge until desired gas pressure is reached.

4. Close manual bleed valve and allow pressure to stabilize.

5. After 5--10 minutes, recheck pressure and adjust accordingly.

6. When correct pressure is reached, remove charging and gaugingunit by performing the following steps:• Turn T--handle counterclockwise until resistance is felt to close

gas valve.• Open manual bleed valve to relieve pressure in gauging unit.• Disconnect gauging unit by unscrewing cap from gas valve.• Re-install valve seal hex cap and tighten to 20 lb. ft. (27 Nm).• Re-install valve protection cap, hand tight.

To increase accumulator pressure to specified pressure (per hydraulicschematic), perform the following steps:

1. Install charging and gauging unit as per Steps 1--3 of “CheckingAccumulator Pre-Charge Pressure” procedure on page 6–28.

2. Allow 5--10 minutes for the gas temperature to stabilize.

3. Turn T-handle clockwise until gauge begins to deflect, then turn itanother full turn.

DangerONLY USE DRY NITROGEN GAS. NEVER USE OXYGEN ORAIR BECAUSE IT COULD CAUSE AN EXPLOSION.

CautionIt is recommended that the commercial nitrogen bottle be equippedwith a regulator to adjust pressure. Full pressure may damage thegauge.

6.8.2 DecreasingAccumulatorPressure

6.8.3 IncreasingAccumulatorPressure

03--006Page 6 of 6

Maintenance Card

6–30 WK03_006_9909

4. Connect charging hose to cap screw adapter and to nitrogen bottledischarge.

5. Purge air in hose so you charge only with nitrogen.

6. Open shut--off valve on nitrogen bottle and slowly fill accumulatorwith dry nitrogen gas. Charging too quickly may damage theaccumulator.

NoteThe gauge on the gauging unit registers the line pressure and notnecessarily the accumulator pressure while charging.

7. Check accumulator pressure as follows:• Close shut-off valve on nitrogen bottle.• Allow gas temperature and pressure to stabilize.• Check accumulator pressure.

8. Fill or release pressure as required until required pressure isreached.

9. When correct pressure is reached, remove nitrogen bottle andgauging unit by performing the following steps:• Close shut--off valve on nitrogen bottle.• Turn T--handle counterclockwise until resistance is felt to close

gas valve.• Open manual bleed valve to relieve pressure in gauging unit.• Disconnect charging hose and remove gauging unit from

accumulator.• Re-install valve seal hex cap and tighten to 20 lb. ft. (27 Nm).• Re-install valve protection cap, hand tight.

To replace the accumulator bladder, take to a qualified hydraulic shop.6.8.4 ReplacingAccumulator Bladder

04--001Page 1 of 8

Maintenance Card

6–31WK04_001_9605GB

This maintenance card describes how to change all the filters in thehydraulic system. You will find the service intervals in the maintenancesummary at the start of this section.



NoteCleanliness is of the greatest possible importance in the maintenanceof hydraulic systems. You must make it impossible for dirt or otherimpurities to enter the system. Even small particles may cause valves tobe scored, pumps to seize and choke and control bores to becomeblocked.

Hydraulic fluid drums must stand for some time before the fluid istaken from them. Never roll the barrels to where you will be drawingoff the fluid. Clean bungs, filler caps and their surroundings beforeopening them.

If possible, you should use a filler unit to fill up the hydraulic system.Never leave the tank lid open longer than necessary.

6.9 Filter Change

04--001Page 2 of 8

Maintenance Card

6–32 WK04_001_9605GB

The following tasks must be carried out before starting the filterchange:

" Switch off the remote control.

" Switch the hydraulic pumps off.

" Switch the drive engine off.

" Reduce fluid pressure to zero.

DangerThe accumulator pressure in pressurized systems must be dumped.

" Secure the system against unauthorized starting – if you haveany keyed switches, remove the key and disconnect the supplyvoltage.

" Secure your working area and fix notices to the blocked controlsand setting devices.

NoteYou must never attempt to clean Micronic filter elements. You mustalways replace them.

Before you fit the new filters, you must check all O--rings and othersealing elements of the filter elements and replace them if damaged.

Environmental protectionDispose of the old filter elements in accordance with the regulations inforce.

Preparation

04--001Page 3 of 8

Maintenance Card

6–33WK04_001_9605GB

Replace the vacuum filter elements once the indications on the vacuummeter are in the red zone. The procedure is as follows:

" Place a container under the drain cock (1) to allow you to catchthe escaping hydraulic fluid.

10400201

1

1 Drain cock

" Unscrew the hexagon nuts to the stop.

" Withdraw the filter element to the stop without turning it.

NoteAn isolating valve interrupts the fluid supply automatically.

" Open the upper stopper to provide an air supply.

" Open the drain cock (1) and allow the hydraulic fluid to run outof the filter casing.

Environmental protectionYou must dispose of the escaping hydraulic fluid in accordance with theregulations in force.

Vacuum filter

04--001Page 4 of 8

Maintenance Card

6–34 WK04_001_9605GB

" Turn the hooked lid to the left and withdraw the filter element.

" Unscrew the hexagon bolt from the bar magnet.

" Turn the filter element to the left and withdraw it from the barmagnet.

" Wipe the bar magnet lengthways with a clean cloth.

" Fit a new filter element and replace the hexagon bolt.

CautionFilter elements freely available on the market have too low a flow rate.You must, therefore, only ever use original Putzmeister filter elementsin order to prevent damage to the machine.

04--001Page 5 of 8

Maintenance Card

6–35WK04_001_9605GB

" Check and, if necessary, set the filter element to the correctiondimension of 346 mm 0.5. The correction dimension is mea-sured from the lower edge of the cover to the tip of the element.

10400401

.

Correction dimension

CautionThe filtering process causes dirt particles to accumulate in the filtercasing. You must, therefore, clean the filter casing thoroughly beforefitting the new filter element, as otherwise the new filter element willbecome clogged very quickly.

" Thoroughly clean the filter casing with a clean cloth.

" Install a new filter element. The installation procedure is the re-verse of the procedure for removing a filter element.

04--001Page 6 of 8

Maintenance Card

6–36 WK04_001_9605GB

Replace the boom filter element if the red button pops out again afterbeing pressed in at operating temperature.

10400601

Checking and replacing boom filter

" Bring the machine up to operating temperature (> 50˚ C).

" Set the maximum output.

" Press the red button on the boom filter.

NoteThe filter is OK if the red button remains depressed.

The filter element must be replaced if the red button pops out again.

Boom filter

Checking

04--001Page 7 of 8

Maintenance Card

6–37WK04_001_9605GB

10400500

Replacing the boom filter

" Undo the filter casing and replace the filter element.

CautionThe filtering process causes dirt particles to accumulate in the filtercasing. You must, therefore, clean the filter casing thoroughly beforefitting the new filter element, as otherwise the new filter element willbecome clogged very quickly.

" Thoroughly clean the filter casing with a clean cloth.

" Install a new filter element.

NoteCheck the level of the contamination indicator. Always replace theprotective cover to the contamination indicator after checking.

Replacing

04--001Page 8 of 8

Maintenance Card

6–38 WK04_001_9605GB

Replace the ventilation filter element if the red check ring is visible inthe inspection glass.

10401903

1

1 Red check ring in the inspection glass

10401902

1

1 Cover

" Remove the cover from the filter casing.

" Replace the filter element.

" Replace the cover.

Hydraulic fluid tankvent filter

Checking

Replacing

04--002Page 1 of 4

Maintenance Card

6–39WK04_002_0106

This maintenance card describes how to check and replace thehydraulic hoses. You will find the service intervals in the maintenancesummary at the start of this chapter.



NoteCheck all hoses (including hose fittings) with the machine running.You must replace the hoses at the slightest sign of damage or even mereindications of threatened damage.

10400800

Check hydraulic hoses

Dark and moist patches on the fitting are external signs of incipientdamage. Check:-- the hoses for kinks, cracks or a porous surface, and-- whether the hoses have been laid without restrictions.

NoteBeware of strong sunlight, the action of heat and the effects ofchemicals.

6.10 Hoses

Leaking hose

04--002Page 2 of 4

Maintenance Card

6–40 WK04_002_0106

10400100

Tighten until there is a clearly perceptible increase inforce

" Check whether the flared screwed joints are tight.

NoteYou may only tighten leaking flared screwed joints with the permittedtorque. Tighten the joint until you clearly feel an increase in the forcerequired if you do not have a torque wrench available. You mustreplace these flared screwed joints if leaking continues.



Md [Nm] Md[Ft--Lb]


Md [Nm] Md[Ft--Lb]

6 L 20 14.8 18 L 120 88.8

8 L 40 29.6 20 S 250 185

12L 55 40.7 25 S 400 296

12S 80 59.2 30 S 500 370

15 L 70 51.8 38 S 800 592

16 S 130 96.2


04--002Page 3 of 4

Maintenance Card

6–41WK04_002_0106

The procedure for replacing hoses is as follows:

" Shut down the machine and secure against unauthorized starting.

" Fully dump any (residual) pressure in the hydraulic system.

DangerHydraulic hoses may be mechanically pre--stressed. There is a risk ofinjury from whipping hoses.

" Take care when undoing the unions.

" Close the connection points with a plug immediately after youhave removed the old hoses. No dirt may enter the hydraulic cir-cuit and the hydraulic circuit must not run empty.

DangerHoses may not be more than six years old, including a storage periodof two years. Take note of the date of manufacture on the hoses.

" Keep the hoses free from dirt.

" Thoroughly clean the inside of the hose.

" Fit the hoses to be free from bends or chafe points.

" Bleed the hydraulic system.

" Carry out a test run and inspect all hoses again after fitting newhoses.

Environmental protectionCatch escaping fluid in a container and dispose of in an environmen-tally friendly manner.

Replacing hoses

04--002Page 4 of 4

Maintenance Card

6–42 WK04_002_0106

04--005Page 1 of 2

Maintenance Card

6–43WK04_005_9909

This maintenance card describes how to replace the vacuum meter andhow to remove the packing piece. You will find the service intervals inthe maintenance summary at the start of this section.



NoteReplace the vacuum meter if it is mechanically damaged or if thedisplay is incorrect, e.g. there is an indication although the machine isnot running.

CautionYou must remove or open the packing piece once you have fitted thenew vacuum meter.

6.11 Vacuum Meter

04--005Page 2 of 2

Maintenance Card

6–44 WK04_005_9909

" Unscrew the old vacuum meter from the vacuum filter.

" Screw the new vacuum meter onto the vacuum filter.

10402000

Venting the vacuum meter

" Open the vent by either cutting off the tip of the packing piece orpiercing the rubber stopper, depending on the design. Do notremove the rubber plug from the gauge.

06--009Page 1 of 10

Maintenance Card

6–45WK06_009_9909

This maintenance card describes how to change the delivery pistons onmachines with KEP. KEP (Piston end--of--travel positioning) is the ballvalve fitted in the stroke equalization line of drive cylinder II (on theleft looking in the direction of travel). You will find the maintenanceintervals in the maintenance summary at the start of this chapter.



NoteYou must rectify damage to the delivery pistons immediately.Putzmeister accepts no warranty claims for damage to the machineresulting from failure properly to observe the maintenance regulations.

DangerSecure the working area. Affix warning notices to the blocked controland setting devices. Never place your hands in or around the waterbox when the engine of the machine is running, since this could resultin severe personal injury or death.

6.12 Change of DeliveryPiston with KEP

06--009Page 2 of 10

Maintenance Card

6–46 WK06_009_9909

When replacing the delivery pistons you will have to start and stop themachine a number of times. The operations necessary for this aredescribed below and must be carried out conscientiously. Carry out allmachine functions from the cable control.

The procedure for shutting down the machine is as follows

" Switch the engine off.

" Press in the EMERGENCY SHUT--DOWN button.

" Dump the pressures completely.

DangerDump the accumulator pressure completely in systems with pressureaccumulators.

The procedure for starting up the machine is as follows:

" Unlock the EMERGENCY SHUT--DOWN button and sound thehorn.

" Switch the engine on.

Shutting down themachine

Starting up the ma-chine

06--009Page 3 of 10

Maintenance Card

6–47WK06_009_9909

Drive cylinder I is located on the right looking in the direction oftravel. You may block drive cylinder I in the end position to make iteasier to remove the delivery piston. This is done as follows:

" Press the “Stroke change--over” button when the concrete pumpis running and hold it down until the concrete pump switches off.

" You must switch the concrete pump off when the drive cylindershave reached the end position. Then you can release the “Strokechange--over” button.

Drive cylinder II is located on the left looking in the direction of travel.The stroke equalization line incorporates a ball valve (KEP) which isfitted open (markings parallel to the line) in the works and is lockedagainst rotation.

20202301

The works fits the KEP valve in the open state

Block drive cylinder Iin the end position

Block drive cylinder IIin the end position

KEP

06--009Page 4 of 10

Maintenance Card

6–48 WK06_009_9909

You may block drive cylinder II in the end position to make it easier toremove the delivery pistons. This is done as follows:

20202302

1

2

1 As--fitted position secured against rotation2 Rotate as--fitted position

" Undo the bolt on the handle and remove the handle.

" Lift up the guide washer and refit it rotated through 90_.

06--009Page 5 of 10

Maintenance Card

6–49WK06_009_9909

20202303

KEP valve closed

" Replace the handles and close the ball valve.

" Press the “Stroke change--over” button when the concrete pumpis running and hold it down until the concrete pump switches off.

" You must switch the concrete pump off when the drive cylindershave reached the end position. Then you can release the “Strokechange--over” button.

06--009Page 6 of 10

Maintenance Card

6–50 WK06_009_9909

When replacing pistons you may work with the remote control on theplatform.

10600301

1 2 3 2 4

5

1 Piston rod flange2 Fastening bolts3 Securing wire4 Delivery piston5 Spacer flange

" Shut the machine down.

" Drain the water from the water box and remove the cover.

" Start the machine up.

" Move the drive piston of the delivery piston to be removed to itsend position. The spacer flange must be fully visible in the waterbox.


" Remove the securing wire from the fastening bolts.

Piston replacement

06--009Page 7 of 10

Maintenance Card

6–51WK06_009_9909

10600701

1

1 Fastening bolts

" Unscrew the fastening bolts for the spacer flange from the drivepiston rod and from the delivery piston and remove the spacerflange.


" Slowly bring the drive piston rod up to the delivery piston.


10600800

1

1 Pulling bolts

06--009Page 8 of 10

Maintenance Card

6–52 WK06_009_9909

" Remove the protective caps from the two pulling bolts and boltthe delivery piston to the drive piston using the two pulling bolts.


" Pull the delivery piston completely out of the delivery cylinder.


" Undo the threaded joint and remove the old delivery piston.

" Thoroughly clean the delivery piston edge at the end of the waterbox.

CautionDo not use any hard objects or caustic cleaning agents to clean thedelivery cylinder. These could damage the chrome layer.

" Grease a new delivery piston heavily with acid--free grease (e.g.,Vaseline).

" Bolt the new delivery piston to the drive cylinder using the twopulling bolts.


" Slowly advance the drive piston rod and push the new deliverypiston carefully into the delivery cylinder. The pulling bolts mustremain freely accessible.


06--009Page 9 of 10

Maintenance Card

6–53WK06_009_9909

" Unscrew the pulling bolts and replace the protective caps.


" Retract the drive piston rod sufficiently for the spacer flange tofit between the delivery piston and the drive piston.


" Insert the spacer flange and fasten all the bolts.

" Tighten the bolts with the specified tightening torques and securethem with a stainless steel wire.

20202301

Open the KEP valve and secure it against rotation

" Open the KEP valve when delivery piston replacement is com-pleted.

" Replace the guide washer so that it is blocked in position, fit thehandle and bolt it down.

" Then carry out a test run.

06--009Page 10 of 10

Maintenance Card

6–54 WK06_009_9909

07--001Page 1 of 2

Maintenance Card

6–55WK07_001_9909

This maintenance card describes the lubrication of all lubrication pointson the transfer tube if you do not have a centralized lubrication system.You will find the maintenance intervals in the maintenance summary atthe start of this chapter.


The following special tools are required:Grease gun

NoteRefer to the “Recommended Lubricants” section on page 6–10 for anappropriate grease to use.

You should grease the lubrication points hourly, unless a differentinterval is specified. At the end of the day to purge grout, you shouldapply the grease until you can see it escaping.

30300103

Transfer tube and plunger cylinder lubrication diagram

6.13 Lubricating theS Transfer Tube

Lubrication intervals

07--001Page 2 of 2

Maintenance Card

6–56 WK07_001_9909

07--011Page 1 of 24

Maintenance card

6 — 57WK07_011_0407

This maintenance card describes how to replace the S transfer tube and itswear parts. You will find the maintenance intervals in the maintenancesummary at the start of this chapter.

Refer also to the maintenance cards:Measuring the wall thickness

You should request the special fitting instructions from us if you have aspectacle wear plate made from a special material (e.g. hard metal, hard castiron, ceramics).


The tightening torques are listed in the “General tightening torques”section at the start of the Maintenance chapter. Torques differingfrom these are specified in the spare parts sheets.

DangerShut down the machine before commencing work and secure it againstunauthorized or accidental starting. Dump the accumulator pressure.

Use only suitable lifting equipment for lifting components.

NoteThe wear parts must be replaced if visual inspection reveals wear or if thereis insufficient pressure build--up in the delivery line.

6.14 S Transfer Tube

Torques

Maintenance card07--011Page 2 of 24

6 — 58 wk07_011_0407en

wk07_011_0407en1

1 2

No. 0 Designation

1 S transfer tube with bolted switching shaft

2 S transfer tube with welded switching shaft

NoteWhatever variant of S transfer tube fitted, the recommended procedure fordismantling is as described below. The S transfer tube with bolted switchingshaft may also be dismantled and reassembled in the hopper. The tube is thendismantled as described in the “S transfer tube with bolted switching shaft”maintenance card.

You should also consult the “Divided hopper” maintenance card if yourmachine has a divided hopper.

S transfer tubevariants

07--011Page 3 of 24

Maintenance card

6 — 59wk07_011_0407en

30300101

32

6514

7

10

8 9 8

No. 0 Designation

1 Plunger cylinder

2 Retaining plate3 Retaining plate fastening bolts4 Clamping bolts with nuts

5 Switch lever6 Hexagon nut on the switching shaft7 Fastening bolt for flanged bearing (10)

8 B fastening bolts for spectacle wear plate9 A fastening bolts for spectacle wear plate10 Flanged bearing

11 (not shown) Two jacking bolts

Overview


6 — 60 wk07_011_0407en

The S transfer tube is mounted in the transfer tube bearing in therear wall of the hopper.

" Open the grille on the hopper and secure it.

" Attach suitable lifting gear to the S transfer tube.

" Remove the lubrication lines from the transfer tube bearing.

108009012

1

1

43

No. 0 Designation

1 Fastening bolts2 Jacking bores with jacking thread

3 Transfer tube bearing4 Hinged elbow

" Swing the hinged elbow (4) to one side.

" Remove the two fastening bolts (1) for the transfer tube bearing (3)and force the bearing out by screwing the two jacking bolts suppliedinto the jacking bores.

" Check the seal rings and O--rings in the transfer tube bearing for wearand replace as required.

Removing the transfertube bearing

07--011Page 5 of 24

Maintenance card

6 — 61wk07_011_0407en

10801000

Bend the seal rings to make installation easier

CautionThe mounting position for the seal set in the transfer tube bearing can befound in the accompanying spare parts sheet.

" Grease the new seal set and fit it as illustrated on the spare parts sheet.

NoteClean the transfer tube bearing before refitting and grease the seals. Checkthe lubricant bores, in particular, for proper functioning. This is done byconnecting the lubrication lines and forcing lubricant through the apertures.

Transfer tube bearingseal set


6 — 62 wk07_011_0407en

The switching shaft of the S transfer tube is mounted in the switchingshaft bearing (flanged bearing) in the front wall of the hopper.

" Remove any lubrication lines on the retaining plate and flanged bear-ing.

10300700

Unbolting the retaining plate

" Undo the fastening bolts on the retaining plate and remove the retain-ing plate. (You will have to replace the locking plates on the fasteningbolts with new ones on reassembly.)

Environmental protectionCollect the escaping hydraulic fluid in a suitable container and dispose of itin accordance with the disposal regulations applicable for your region.

" If necessary for space reasons, disconnect the hydraulic hoses leadingto the plunger cylinders at the bulkhead unions. Then close off the hy-draulic lines with plugs.

Removing the switch-ing shaft bearing(flanged bearing)

07--011Page 7 of 24

Maintenance card

6 — 63wk07_011_0407en

10300800

Removing the plunger cylinders

NoteThe plunger cylinders can be pushed back as illustrated. It is, however, alsopossible to screw a bolt into the jacking bores for the ball cups and to pushthe plunger cylinders out with the ball cups.

" Push back the pistons in the plunger cylinders and remove the plungercylinders with the hydraulic hoses.

" Undo the hexagon nut on the switching shaft and remove the spacerring.

10700200

Loosening the clamping bolts

" Undo the clamping bolts on the switch lever.


6 — 64 wk07_011_0407en

" Spread the switch lever apart by screwing the two jacking bolts sup-plied into the two bores.

" Withdraw the switch lever from the switching shaft.

10700300

12

3

No. 0 Designation

1 Fastening bolt2 Jacking bores (2 diagonally opposed)

3 Flanged bearing

" Unscrew the fastening bolt (1) from the flanged bearing (3).

" Force the flanged bearing off by screwing the two jacking bolts sup-plied into the jacking bores (2).

" Check the seal rings and O--rings in the flanged bearing for wear andreplace these as required.

07--011Page 9 of 24

Maintenance card

6 — 65wk07_011_0407en

10700400

Removing the retaining ring

" Remove the retaining ring.

10700500

Removing the old seal set

" Remove the old seal set. It may be necessary to cut the seal rings to dothis.

Flanged bearingseal set


6 — 66 wk07_011_0407en

10700600

Fitting the new seal set

CautionThe mounting position for the seal set in the flanged bearing can be found inthe accompanying spare parts sheet.

" Grease the new seal set and fit it as illustrated on the spare parts sheet.

NoteClean the flanged bearing before refitting and grease the seals. Check thesleeve for wear and replace if necessary.

07--011Page 11 of 24

Maintenance card

6 — 67wk07_011_0407en

10700800

Pushing the S transfer tube to one side

" Push the S transfer tube away from the spectacle wear plate.

30300102

1 2 1

No. 0 Designation

1 B fastening bolts2 A fastening bolts

" Undo the 8 fastening bolts and remove the spectacle wear plate fromthe transition liner.

Removing the spec-tacle wear plate


6 — 68 wk07_011_0407en

Replace the S transfer tube if the wall thickness has fallen below theminimum.

Maintenance card: Measuring the wall thickness

NoteIf there is no need to replace the S transfer tube or the wear sleeve in the Stransfer tube outlet, you may skip this operation and continue at the “Fittingthe spectacle wear plate” operation.

10801200

Removing the agitator shaft

" Remove the agitator shaft.

Removing the S trans-fer tube

07--011Page 13 of 24

Maintenance card

6 — 69wk07_011_0407en

10700900

Lifting out the S transfer tube

" Unbolt the scratch bar from the bottom of the S transfer tube.

" Push the S transfer tube forwards until the transfer tube outlet is free.

" Lift the S transfer tube outlet opening first upwards and out.

NoteIf you wish only to replace the wear sleeve, you must also carry out theoperations on the next page and only then fit the S transfer tube again.

If you are replacing the complete S transfer tube, fit the new tube in thereverse sequence to disassembly.

" Fit the new S transfer tube.


6 — 70 wk07_011_0407en

The wear sleeve can be replaced without the requirement to replacethe S transfer tube if the wear sleeve is heavily worn. The S transfertube must be removed to do this.

DangerThere is a risk of burning during heating and fitting of the new wear sleeve.Use suitable protective equipment.

CautionDo not damage the transfer tube when cutting off the wear sleeve.

10701001

Wear sleeve

" Carefully cut the wear sleeve at two opposing points using an anglegrinder and remove the two parts.

NoteThe wear sleeve is chrome--plated and therefore must not be heated locallyor to too great a temperature.

" Heat the new wear sleeve uniformly to a maximum temperatureof 140 _C.

" Place the heated wear sleeve over the transfer tube outlet and allowthe wear sleeve to cool.

" Replace the S transfer tube.

Replacing thewear sleeve in theS transfer tube

07--011Page 15 of 24

Maintenance card

6 — 71wk07_011_0407en

Screw two short threaded rods into the two upper threaded bores inthe spectacle wear plate and insert these into the upper holes in thehopper wall to make positioning of the spectacle wear plate easierduring fitting.

" Check the O--rings in the intermediate rings on which the spectaclewear plate is placed.

" Clean the mounting surfaces and grease them with a multipurposegrease.

CautionThe spectacle wear plate rests only against the O--rings of the intermediaterings. There is a small clearance between the spectacle wear plate and thehopper wall. The B fastening bolts (outer fastening bolts) should thereforeinitially only be tightened finger--tight, as otherwise the spectacle wear platemay be broken.

10801300

Fitting the spectacle wear plate

" Fit the new spectacle wear plate.

Fitting the spectaclewear plate


6 — 72 wk07_011_0407en

30800101

1

2

max. 0.5 mm

No. 0 Designation

1 Spectacle wear plate2 Intermediate ring

" Put the new spectacle wear plate in place and fasten it with the B fas-tening bolts (outer fastening bolts). Tighten these only to finger--tight-ness initially.

" Bolt down the spectacle wear plate with the A fastening bolts (top andbottom) and tighten them to the appropriate tightening torque.

" Tighten the B fastening bolts to the tightening torques given in theaccompanying spare parts sheet. The spectacle wear plate may only bedistorted by a maximum of 0.5 mm when the bolts are tightened.

07--011Page 17 of 24

Maintenance card

6 — 73wk07_011_0407en

Replace the wear ring in the event of heavy visible wear, if concreteis leaking or if there is inadequate pressure build--up in the deliveryline.

10701002

12

No. 0 Designation

1 Thrust ring2 Wear ring

" Remove the old wear ring and the thrust ring.

" Fit a new thrust ring and a new wear ring in the S transfer tube.

Replacing thewear ring


6 — 74 wk07_011_0407en

10800900

Transfer tube bearing

NotePay attention to the location of the lubrication openings when fitting thetransfer tube bearing.

" Fit the transfer tube bearing on the S transfer tube outlet and bolt itsecurely.

Fitting the transfertube bearing

07--011Page 19 of 24

Maintenance card

6 — 75wk07_011_0407en

10701100

Locating the collared washer

" Bend the tab on the collared washer downwards.

" Place the collared washer on the flanged bearing housing so that thetab is located in the bore, thereby securing the washer against rotation.

" Insert the wear sleeve into the flanged bearing housing.

NoteNote the location of the lubrication bores when fitting the flanged bearing.

" Grease the inside of the wear sleeve with “Anti--Seize AS 450 Assem-bly Paste” or an equivalent assembly grease.

" Locate the complete flanged bearing on the switching shaft and bolt ittight.

" Locate the wear sleeve on the switch lever.

Wear sleeve and col-lared washer


6 — 76 wk07_011_0407en

wk07_011_0407en2

Aligning the switch lever

NoteThe topmost tooth of the switching shaft is slightly flattened and may be usedas a marker.

" Grease the teeth on the switch lever and the switching shaft with“Anti--Seize AS 450 Assembly Paste” or an equivalent assemblygrease.

" Fit the switching lever in such a way that the flattened tooth on theswitching shaft is located in the notch in the switching lever and thewear sleeve is form--fitted on the switching lever.

Mounting theswitch lever

07--011Page 21 of 24

Maintenance card

6 — 77wk07_011_0407en

30300101

21 3

No. 0 Designation

1 Spacer ring

2 Switching shaft3 Hexagon nut

" Fit the spacer ring (1) on the switching shaft (2) and screw the hexa-gon nut (3) onto the switching shaft.

NoteThe gap (clearance between wear ring and transfer tube) must be set toensure that the transfer tube switches correctly.


6 — 78 wk07_011_0407en

wk07_011_0407en31 2 3 4

7 6 5

No. 0 Designation

1 Spectacle wear plate

2 Wear ring3 Transfer tube4 Thrust ring

5 Hexagon nut6 Gap between wear ring and transfer tube7 Wear ring is flat against the spectacle wear plate

" First tighten the hexagon nut (5) on the switching shaft so that thewear ring (2) lies flat (7) against the spectacle wear plate (1).

" Then slowly tighten the hexagon nut (5) further until the transfertube (3) lies against the wear ring (2).⇒ This will prestress the thrust ring (4).

" Then undo the hexagon nut (5) on the switching shaft by about ¾ of aturn. This will automatically set the gap required (6) between thetransfer tube (3) and the wear ring (2).⇒ A small gap is created between the wear ring and the transfer tube.⇒ The wear ring is pressed against the spectacle wear plate by thelightly prestressed thrust ring.

07--011Page 23 of 24

Maintenance card

6 — 79wk07_011_0407en

NoteUse only new nuts for the clamping bolts.

" Insert the two clamping bolts in the switch lever and fit new nuts.Tighten the clamping bolts in accordance with the “General tighteningtorques” table.

" Further assembly is carried out in the reverse sequence to disassembly.

NoteThe hydraulic lines must be bled after reassembly. Do this by starting up thepump slowly and switching the transfer tube across slowly a few times.


6 — 80 wk07_011_0407en

10--007Page 1 of 6

Maintenance Card

6–81WK10_007_9909

This maintenance card describes how to measure the wall thickness ofdelivery lines. You will find the service intervals in the maintenancesummary at the start of this section.


The following special tools are required:Wall thickness measuring device

NoteDelivery lines are subject to constant wear. Measurement of the wallthickness is particularly important before starting on large jobs.You will obtain reliable results for your measurements if you carry outthe test with the measuring device recommended by Putzmeister.

Danger of explosionThe delivery line can burst if it reaches the right delivery pressure, par-ticularly if a blockage has built up, if the wall thickness of the deliveryline has declined below the minimum required.

CautionOnly tap the delivery line with hardwood (hammer handle). Otherwisedents may be caused which lead to even faster wear. In addition, thehardened lining of high wear resisting pipes may flake off the inside ofthe pipe. The pipe can burst at points that have suffered heavy wear.

6.15 Measuring theWall Thickness(Machines withS Transfer Tube)

10--007Page 2 of 6

Maintenance Card

6–82 WK10_007_9909

11000101

Tapping the delivery line with a hammer handle

Uniform wear can be achieved by regularly rotating the straightdelivery pipes 120˚.The minimum wall thickness for straight pipes is shown in thefollowing graph.

Uniform wear can be achieved by regularly rotating the elbows 180˚.The wear on the external radius of an elbow is greater than that on theinternal radius or on straight pipes. You should, therefore, take specialcare when measuring the wall thickness of the external radius of anelbow.The minimum wall thickness for elbows is shown in the followinggraph.

11000200

Rotate delivery pipes and elbows regularly

Straight pipes

Elbows

10--007Page 3 of 6

Maintenance Card

6–83WK10_007_9909

The minimum wall thickness for the S transfer tube depends on themaximum possible operating pressure. Furthermore, the fact that thetransfer tube is subject to greater stress at the point at which the torqueis applied (switching shaft -- transfer tube connection) must be takeninto consideration.

12501601

Area of significant loading

Maximum possible operating pressure Guide value for wall thickness

up to 130 bar approx. 3 mm

over 130 bar approx. 5 mm

NoteWe must emphasis the fact that the transfer tube is subject to variabledegrees of loading as a consequence of the dynamic loading duringpumping. There is no general method for calculating this loading,which depends on the individual circumstances, and so the delivery linecan also burst at an operating pressure which is assumed still to bepermissible.

You should also note that the operating pressure can rise to themaximum pressure in the event of a blockage, and in this case the wallthickness may no longer be adequate.

S transfer tube

10--007Page 4 of 6

Maintenance Card

6–84 WK10_007_9909

Follow the operating instructions supplied with the measuring devicewhen carrying out measurements. Do not measure the wall thickness ofthe delivery line at just one point, but around the entire circumferenceof the delivery pipes.The minimum wall thickness is shown in the following graph.

CautionPipes and elbows must be replaced as soon as the wall thickness hasdeclined to the value for the minimum wall thickness.Putzmeister accepts no liability if the wall thickness falls below theminimum.

NoteAs a rule it is possible to continue pumping with a lower operatingpressure than that shown in the graph.

We should, however, draw your attention to the fact that the deliveryline is subject to varying loading as a result of the dynamic loadingduring pumping. There is no general method for calculating thisloading, which depends on the individual circumstances, and so thedelivery line can also burst at an operating pressure which is assumedstill to be permissible.

Furthermore, the operating pressure can rise to 85 bar in the eventof blockages, meaning that the wall thickness will no longer beadequate and the delivery line will burst.

Measuring

10--007Page 5 of 6

Maintenance Card

6–85WK10_007_9909

Minimum wall thickness as a function of operating pressure

0

10

20

30

40

50

60

70

80

90

100

110

120

130

140

150

160

170

180

190

200

210

220

230

240

250

0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0 7.5 8.0 8.5 9.0 9.5 10.0[mm]

[bar]

1

2

1 High pressure2 Maximum delivery pressure

Graph

10--007Page 6 of 6

Maintenance Card

6–86 WK10_007_9909

20--044Page 1 of 2

Maintenance Card

6–87WK20_044_0102

This maintenance card describes the lubrication of all lubrication pointson the placing boom if you do not have a centralized lubricationsystem. You will find the maintenance intervals in the maintenancesummary at the start of this chapter.



NoteRefer to the “Recommended Lubricants” section on page NO TAG foran appropriate grease to use.

You should grease the lubrication points every week, unless a differentinterval is specified. You should apply the grease until you can see itescaping.

WK20_044_0102 4

M 36Z placing boom lubrication diagram

6.16 Lubricating theM 36Z Placing Boom

Lubrication intervals

20--044Page 2 of 2

Maintenance Card

6–88 WK20_044_0102

21--011Page 1 of 2

Maintenance Card

6–89WK21_011_9909

This maintenance card describes the lubrication of all lubrication pointson the boom pedestal if you do not have a centralized lubricationsystem. You will find the maintenance intervals in the maintenancesummary at the start of this chapter.




You should grease the lubrication points daily, unless a differentinterval is specified. You should apply the grease until you can see itescaping.

6.17 Lubricating theBoom Pedestal(TRDI 70)

Lubrication Intervals

21--011Page 2 of 2

Maintenance Card

6–90 WK21_011_9909

Lubrication Points with No Central Lubrication Manifold

Lubrication Diagram for TRDI 70 Boom Pedestal

Lubrication Points with Central Lubrication Manifold

Lubrication Diagram for TRDI 70 Boom Pedestal

25--001Page 1 of 8

Maintenance Card

6–91WK25_001_9909

This maintenance card describes how to replace the delivery line andits seals. You will find the maintenance intervals in the maintenancesummary at the start of this chapter.

Refer also to the maintenance cards:Measuring the wall thickness

The following special tools are required:4 mm feeler gauge

The delivery line is subdivided into two sections:-- Boom delivery line-- Pump--boom delivery line.

These comprise:-- bends;-- straight pipes of uniform length;-- adapter pipes (straight pipes manufactured individually for each armpackage in order to fit the delivery line to the arm lengths).

Measure the wall thickness of the delivery line to determine which pipesections need to be replaced.

Maintenance card: Measuring the wall thickness

The starting points for laying the pipe on the boom are the hinge pivotpoints. The straight sections of the delivery line run from pivot point topivot point. The delivery line is matched to the arm length concernedby means of the adapter pipes. The length of the pump--boom deliveryline is also adapted by means of adapter pipes.

6.18 Replacing theDelivery Line

General

Wall thickness

25--001Page 2 of 8

Maintenance Card

6–92 WK25_001_9909

1

2

3

4

5

6

7

8

1 First adapter pipe on A arm (L1)2 Second adapter pipe on A arm (L1.1)3 First adapter pipe on B arm (L2)4 Second adapter pipe on B arm (L2.1), etc.5 First pipe in pump -- boom delivery line (V1)6 Second pipe in pump -- boom delivery line (V2), etc.7 V8 and V9 are adapter pipes for lateral outlets8 V10 is always the riser pipe

The length of the adapter pipes differs according to the machine andboom. For re--ordering purposes, you should take the lengths andlocation of all the adapter pipes on your machine from the adapterpipes plate next to the rating plate or from the following spare partssheets:-- Boom delivery line: Spare parts sheet group 25.0-- Pump--boom delivery line: Spare parts sheet group 25.3

The adapter pipe lengths plate is located on the boom

Adapter pipe lengthplate

Ordering

25--001Page 3 of 8

Maintenance Card

6–93WK25_001_9909

When ordering adapter pipes you should always state:-- Machine number Example: 22/.....-- Mounting position L3.1-- Length in mm 1377 mm-- Diameter DN DN 125

CautionYou must not exceed the delivery line wall thickness specified onthe rating plate and in the machine card. The additional weight canimpair the machine’s stability.

NoteShould you wish to re--equip your machine to a delivery line of greaterwall thickness, the machine’s stability will have to be recalculated andchecked and approved by an authorized inspector.

The boom delivery line must be fitted with the arm assembly fullyrelieved of tension:-- the arm assembly is not under tension in the transport position ifeach arm is lying freely on the rest provided for this purpose;

-- the arm assembly is not under tension when unfolded if each arm issupported.

CautionIf the tension on the arm package is not fully relieved during assembly,stresses may occur in the delivery line on movement of the placingboom and consequential damage may be caused to the pipe bracketsand to the placing boom. Furthermore, the boom may swing up anddown causing the end hose to swing and strike out during pumpingoperations.

Untensionedassembly

25--001Page 4 of 8

Maintenance Card

6–94 WK25_001_9909

A clearance of 4 mm must be maintained between the delivery pipesover the whole of the delivery line, so that the welding neck rings canbutt against the couplings without play. This clearance is achievedeither:-- automatically, through the use of a C seal (triple--lip seal), or-- manually, by adjustment, using a feeler gauge.

C seals (triple--lip seals) are used where the delivery line runs in astraight line and there is no rotational movement. The 4 mm clearanceis created automatically.

CautionNo triple--lip seals (C seals) may be used in the pivot joints in the pipebends.

A seals are used:-- if the delivery line does not run in a straight line;-- in the pivot joints; and-- at the assembly coupling at the tip of the boom.The spacing of 4 mm must be set using the feeler gauge.

Couplings with lever closures must be secured with a spring clip.

11000800

Securing couplings with lever closures

Couplings with a threaded closure are closed using self--locking nuts.These nuts may not be re--used, but must be replaced each time thecoupling is fitted.

Clearance

Seal

Coupling

25--001Page 5 of 8

Maintenance Card

6–95WK25_001_9909

4 mm

Set the spacing with the feeler gauge

" Push the A seal over the fixed delivery line pipe.

" Lay the pipe to be attached in the pipe bracket and push it up tothe fixed pipe.

" Set the clearance of 4 mm between the pipes using a feelergauge.

" Fix the pipe to be attached in the pipe brackets.

" Push the A seal over the two weld--on rings.

" Fit the coupling and secure it.

Fitting an A seal

25--001Page 6 of 8

Maintenance Card

6–96 WK25_001_9909

CautionNo triple--lip seals (C seals) may be used in the pivot joints.

4 mm

The spacing is created automatically by the ring seal

" Push the C seal over the welded--on ring of the fixed deliveryline pipe.

" Lay the pipe to be attached in the pipe bracket and push it up tothe fixed pipe.

" Push the pipe to be attached as far as the stop in the ring seal.

" Fix the pipe to be attached in the pipe brackets.

" Fit the coupling and secure it.

Fitting a C seal

25--001Page 7 of 8

Maintenance Card

6–97WK25_001_9909

The starting points for laying the pipe on the boom are the pivot points.

" Grease all couplings and seals well internally before assembly.


" Install the bends in the fitting couplings at the pivot points.

" Align the bends such that the straight pipes can be connectedwithout tension.

" Fix the bends.

" Install the fixed length delivery pipes.

" Install the adapter pipes last.

Boom delivery line

25--001Page 8 of 8

Maintenance Card

6–98 WK25_001_9909

The pressure pipe is the starting point for assembly.

NoteYou should use only high--pressure pipes when replacing these deliveryline pipes.Only C seals (triple--lip seals) are used throughout the pump--boomdelivery line.

" Grease all couplings and seals well internally before assembly.


" Fit the reducer pipe to the pressure pipe with a clamp coupling.The clamp coupling must be capable of rotating with the pres-sure pipe. The reducer pipe, which must be located in a vibrationabsorber, may not turn either.

" Fit the boom connection pipes as far as the bend on the riserpipe.

Pump-boomdelivery line

A820062_07_0208D 7–1

7 Troubleshooting Guide

The previous sections of this manual dealt with the various aspects ofoperation, preventative maintenance, adjustments, and componentreplacement. This troubleshooting section will assist you inrecognizing and recovering from conditions that cause equipmentmalfunctions.


7.1 Concrete Pump 7–2

7.2 Placing Boom 7–8

7.3 Boom Control 7–9

7.4 Electrical System 7–9

Troubleshooting Guide

A820062_07_0208D7–2

This section describes the possible causes of defects which may affectthe concrete pump and how to rectify them. The numbers inparentheses are the item numbers on the hydraulic schematic.

The delivery pistons do not start

Cause Remedy

Pump not switched on With truck transmission in neutral and parking brake on, start truckengine and engage concrete pump PTO. Verify that green PTO lightilluminates and place in correct pumping gear.

Lack of fluid in the hydraulicsystem

Top up hydraulic fluid.

No accumulator pressure( di f i d

On older machines, close accumulator dump valve (121).(see test reading for requiredvalue)

120

119

119

On newer machines, verify that hopper grate is closed and then manuallypush solenoid-operated accumulator dump valve (184) to see ifaccumulator pressurizes. If accumulator pressurizes (when dump valveis pressed), problem is in the dump valve or its circuitry.

119

181

120184

Vacuum meter (136) in thered zone

Vacuum filter (140) dirty. Replace filter element (141), cleanmagnetic rod, observe maintenance intervals.

7.1 Concrete Pump


A820062_07_0208D 7–3

The delivery pistons do not start

Cause Remedy

Hydraulic fluid too cold Allow hydraulic fluid to warm up by idling.

Main hydraulic system pump(127) not engaged foroperation

Increase delivery rate regulation by:(1) Using electric volume control switch (211), or

(2) Closing manual volume control valve (125)

Delivery piston blocked inh d i i

Press reverse pumping switch or stroke change switch.the end position

10600100

Engine speed too low. Themain pump does not engage.

Increase engine speed.

Pump has insufficient output

Cause Remedy

Main hydraulic system pump(127) not fully engaged

Increase delivery rate regulation by:(1) Using electric volume control switch (211), or(2) Closing manual volume control valve (125)


A820062_07_0208D7–4

Pump is not running

Cause Remedy

Lack of fluid, machineswitches off automatically


Stroke change valve (103a)sticks as a result of fine dirtor defect

Press stroke change valve manual operation button (103a) a number oftimes, switch the pump over to reverse pumping for 2 -- 3 strokes. Checksolenoid coils and their connections.

184

106

119 181

120

121

125211

183142

108

196103a


A820062_07_0208D 7–5

Pump does not switch over

Cause Remedy

Too little hydraulic fluid Top up hydraulic fluid.

Fuse blown Replace fuse.

Stepping relay in the switchcabinet defective

Operate stroke change function. Verify that LED on the stroke changemodule illuminates during cycle. If LED does not illuminate, checkstepping relay.

Stroke change valve (103a)sticks as a result of fine dirtor defect

Press stroke change valve manual operation button (103a) a number oftimes, switch the pump over to reverse pumping for 2 -- 3 strokes. Checksolenoid coils and their connections.

184

106

119 181

120

121

125211

183142

108

196103a


A820062_07_0208D7–6

Transfer tube does not switch or gets stuck

Cause Remedy

Insufficient accumulatorl i i

On older machines, close accumulator dump valve (121).pressure, accumulator circuitnot pressurized (see testreading for required value),change-over pressure is toolow, or accumulator dumpvalve (184) is open.

120

119

119

On newer machines, verify that hopper grate is closed and then manuallypush solenoid-operated accumulator dump valve (184) to see ifaccumulator pressurizes. If accumulator pressurizes (when dump valveis pressed), problem is in the dump valve or its circuitry.

119

181

120184

Accumulations of aggregatein the range through whichthe transfer tube swings,deposits in the hopper

Remove by repeated change-over and reverse pumping, if necessary,open hopper and clean. Request concrete complying with the standard.Set transfer tube hard/soft shift valve (181) to “hard shift” position (i.e.,open).

Accumulator empties too quickly or no pressure

Cause Remedy

Hopper grate is open orsolenoid-operated dumpvalve (184) is not operatingproperly

Verify that hopper grate is closed and then manually pushsolenoid-operated accumulator dump valve (184) to see if accumulatorpressurizes. If accumulator pressurizes (when dump valve is pressed),problem is in the dump valve or its circuitry.


A820062_07_0208D 7–7

Hydraulic fluid is getting too hot

Cause Remedy

Too little cooling water inh b hi h

Top up the water.the water box at high output

10600200

Cooling water too hot Replace with fresh water.

Too little fluid in thehydraulic system


Pump is running in themaximum pressure rangebecause of poor concrete andhigh delivery rate

Reduce pump delivery speed or ask for better concrete (composition).

Constantly at maximumpressure in long--distancedelivery

Increase pipe size, eg from 4” (DN 100) to 5” (DN 125).

Overpressure as a result of ablockage

Remove blockage (by switching the pump over from delivery to reversepumping a number of times).

10600100

Radiator (132) dirty, radiatorfan not running

Switch on.Clean.Check voltage and ground contact of thermocouple 131˚F(55˚C)(not on front--mounted radiator).


A820062_07_0208D7–8

This section describes the possible causes of defects which may affectthe boom and how to rectify them.

DangerOnly carry out maintenance and repair work on the placing boom if theplacing boom is retracted or properly supported, the engine is switchedoff and the support legs are secured.

12000401

Supporting the boom

The boom can be slewed in a full circle without limitation (machines with slewing geartransmission)

Cause Remedy

The slewing gear limitswitch is defective or thelimit switch actuator is bent

Repair slewing gear limit switch.

CautionThe hydraulic and electric lines can be damaged if themast is slewed in the same direction anumber of times.

7.2 Placing Boom


A820062_07_0208D 7–9

This section describes the possible causes of defects affecting theproportional boom control and how to remedy them.

Boom control has failed completely, no boom arm or support foot can be shifted

Cause Remedy

EMERGENCY OFFfunction has been activated

Unlock all EMERGENCY SHUT--DOWN push-buttons. If necessary,change from the radio control system to the cable control.

The mode select operatingvalve does not become livewhen the boom control isswitched on

Check fuses. Operate EMERGENCY SHUT--DOWN valve by hand. Ifnecessary, replace EMERGENCY SHUT--DOWN valve.

Emergency measure:Execute individual boom functions by the manual lever with theEMERGENCY SHUT--DOWN valve pressed in.

This section describes the possible causes of faults in the electricalsystem and how to rectify them.

The radio transmitter has to be shaken to activate it

Cause Remedy

The batteries haveinadequate contacts in thebattery compartment

Clean the contacts in the battery compartment thoroughly and bendcarefully.

Pump is switched on, but will not start

Cause Remedy

The specified minimumengine speed for pumping

i f 900 i

Increase engine speed.

operations of 900 rpm is notachieved

7.3 Boom Control

7.4 Electrical System


A820062_07_0208D7–10

Pump is switched on, but will not start

Cause Remedy

Pumping rate too low Increase pumping rate.

EMERGENCYSHUT DOWN i i d

Unlock all EMERGENCY SHUT--DOWN buttons.SHUT--DOWN is activated(EMERGENCYSHUT--DOWN buttonpressed)

10500200

The red indicator light for “fluid overheating” is lit

Cause Remedy

The hydraulic fluid hasoverheated

Allow the hydraulic fluid to cool and, if necessary, top up orreplace the water in the water box.

The fan on the heatexchanger is defective

Check fan function and replace the fan motor if necessary.

Temperature sensor B1 isdefective

Replace temperature sensor. Hold temperature sensor connection toground to check.

The connection cable to thetemperature sensor is loose

Clean and fasten the connections on the temperature sensor.


A820062_07_0208D 7–11

The red indicator light for “fluid overheating” is lit

Cause Remedy

The fan connection iscorroded

Clean the terminals on the fan motor and fasten the connection cablesproperly.

CautionAvoid contact with ground.

The vibrator fuse is blown

Cause Remedy

The vibrator is defective orthe hopper grate is loose

Replace defective vibrator. Fasten the grate cover on the hopper andreduce the out--of--balance of the vibrator, if necessary.

Vibrator cable is damaged Replace vibrator cable.


A820062_07_0208D7–12

The fan on the oil cooler no longer switches in automatically

Cause Remedy

Thermal contact switch B2defective (seat on the

Check terminal (and ground contact). Replace thermal contact switch (donot forget copper gasket). Switch on cooler motor by the manual switch.

connecting flange of thecooler)

10501100

The radio remote control no longer operates perfectly, some functions are incorrect

Cause Remedy

Fuses in the receiver ortransmitter have blown

Check fuses.To replace transmitter fuse, open transmitter casing with 4 mm allen key.To check the fuse in the receiver, unscrew casing lid, undo the frontprinted circuit board (PCB) and flap down. The microfuses are mountedon the rear PCB. The current ratings are marked next to the fuses.

The engine speed reduces spontaneously

Cause Remedy

EMERGENCYSHUT--DOWN pulses fromthe radio control system

Brief EMERGENCY SHUT--DOWN pulses from the radio controlsystem can be caused by radio interference. If necessary, move thetransmitter site. In some circumstances on particular construction sites itwill be necessary to work with the cable remote control system. Changechannel if the radio control system has channel selection.


A820062_07_0208D 7–13

The pump no longer switches over on every other stroke

Cause Remedy

Defective proximity switch,cable, or junction box.

Refer to “Proximity Switch Junction Box” section on page 3–36 and“Proximity Switch Connector” section on page 3–38. Replace defectivecomponent(s).

NoteOn older models (with proximity switches in the waterbox), a red LED on the side of the proximity switcheslights up when they are approached with a metallic ob-ject (but not touched).

One coil on the strokeh l (103 ) i

Replace stroke change valve (103a).change valve (103a) isdefective

184

106

119 181

120

121

125211

183142

108

196103a

Connecting plug on thestroke change valve (103a)corroded

Check connector on the stroke change valve (103a).


A820062_07_0208D7–14

Index

Index A–1

Aaccumulator, 3–47- maintenance, 6–27- troubleshooting, 7–6

accumulator dump cock, 3–47

accumulator dump valve, 3–47

agitator hopper, pumping operations, 5–41

agitator lever, 3–45

agitator safety cut--out, agitator shut--off valve, 3–41

agitator shut--off valve, 3–41

Antennae, Radio, telephone etc., 3–31

Bbad weather, 5–28

blockages, 5–46

boom- bounce, 5–42- description of the functions, 3–6- favorable boom position, 5–42- impermissible working range, 5–39- rating plate, 3–4- troubleshooting, 7–8- unfolding, 5–34

boom control, troubleshooting, 7–9

boom control unit, inspection, 5–6

boom movements, 5–27- danger zone, 5–29- hand signals, 5–33- high voltage lines, 5–30- horn, 5–31- prohibited activities, 5–27- uncontrolled boom movements, 5–32- uncontrolled sinking as a result of hydraulic fluid cooling,5–31

bouncing boom, 5–42

breaks in pumping, 5–45

Ccable remote control, 3–26- setup, 5–20

catch basket, 5–52

central module control cabinet, multiple display, 3–18

centralized lubrication system- grease, 6–8- indicator lamps, 3–24- low temperature grease, 6–8- technical data, 3–23

charging and gauging kit, 6–25

cleaning- catch basket, 5–52- cement bags, 5–54- compressed air cleaning, 5–52- concrete pump, 5–50- delivery cylinder, 5–61- delivery line, 5–56- high--pressure water cleaning, 5–54- hopper, 5–61- leavings, 5–51, 5–61- mark the water hose, 5–55- methods of cleaning delivery lines, 5–57- post--washing operations, 5–64- preparations for cleaning, 5–50- S--tube, 5–61- sponge ball, 5–51- suction cleaning, 5–58- truck superstructure, 5–64- wash--out adapter, 5–53

clearances- high voltage lines, 5–30- minimum clearance from pits, 5–9- safe clearances from pits, 5–10

cold weather, 5–28

components, summary, 3–2

compressed air cleaning, 5–52

concrete brake, 3–52

concrete pump, description of the functions, 3–7

control block- boom, 3–44- outriggers, 3–43

control cabinet, central module control cabinet, 3–16

control devices- agitator lever, 3–45- boom control block, 3–44- cable remote control, 3–26- central module control cabinet, 3–16- control panel in the steps, 3–21- hydraulic fluid radiator, 3–55- output controller, emergency operation, 3–49- outriggers control block, 3–43- proximity switch junction box, 3–36- radio remote control, 3–28

Index

IndexA–2

- vibrator, 3–54- water pump lever, 3–46

control panel, in the steps, 3–21

coolant overheating, 3–19

corner bearing load, 5–14

Ddanger zone- boom movements, 5–29- pumping operations, 5–40- setup site, 5–12

delivery cylinder, cleaning, 5–61

delivery linecleaning, 5–56- description of the functions, 3–6- measuring the wall thickness (machines with S transfertube), 6–81

- replacing, 6–91

delivery piston- piston replacement with KEP, 6–45- troubleshooting, 7–2

driving, 4–2- during the journey, 4–3

EEMERGENCY SHUT--DOWN button, 3–31, 3–34, 5–6

EMERGENCY SHUT--DOWN function, 5–5

emergency stroke kit, 5–72

End hose- Extending, 2 — 6- With spout, 2 — 6

end hose, 3–51, 5–40- concrete brake, 3–52- danger zone, 5–40- retaining rope, 3–53- with flow restrictor, 3–52

engine, troubleshooting, 7–12

Ffilter- boom filter, 5–4- vacuum filter, 5–4

filter change, 6–31

filter functions- boom filter, 5–4- vacuum filter, 5–4

flared screwed joint, 6–6

flow restrictor on the end hose, 3–52

flushing water pump, 3–50

function checks, 5–3, 6–23- boom control unit inspection, 5–6- EMERGENCY SHUT--DOWN function, 5–5- filter functions, 5–4- proximity switch, 5–3- pump functions, 5–3

function description, 3–6- boom, 3–6- concrete pump, 3–7- delivery line, 3–6- hydraulic control, 3–6- outriggers, 3–6- transfer tube, 3–7

functional fluids, 6–7

fuse, troubleshooting, 7–11

Hhand signals- boom movements, 5–33- pumping operations, 5–33

high voltage lines, 5–30

high--pressure water cleaning, 5–54

highway travel, 4–2

hopper, cleaning, 5–61

hopper grate safety switch, 3–39

hoses, maintenance, 6–39

hydraulic control, description of the functions, 3–6

hydraulic fluid, 6–7- full fluid change, 6–17- radiator, 3–55- troubleshooting, 7–7, 7–10

hydraulic fluid radiator, 3–55

hydraulic system- accumulator maintenance, 6–27- charging and gauging kit, 6–25

Iicons, 1–3

Index

Index A–3

KKEP, piston end--of--travel positioning, 6–45

Lleavings, 5–51, 5–61

leveling bubble, 5–25

Liability, Exclusion, 2 — 9

Lifting loads, 2 — 5

loading, 4–8

lubricant analysis, 6–9

lubricants (recommended), 6–10

lubrication- grease, 6–8- M 36Z placing boom, 6–87- S transfer tube, 6–55- TRDI 70 boom pedestal, 6–89

MM 36Z, lubrication, 6–87

machine rating plate, 3–3

Maintenance cards- Replacing the S transfer tube, 6 — 57- S transfer tube wear parts, 6 — 57

maintenance cards- changing the hydraulic fluid, 6–17- delivery piston replacement with KEP, 6–45- filter change, 6–31- function checks, 6–23- hoses, 6–39- lubricating the M 36Z placing boom, 6–87- lubricating the S transfer tube, 6–55- lubricating the TRDI 70 boom pedestal, 6–89- measuring the wall thickness (machines with S transfertube), 6–81

- performing maintenance on the accumulator, 6–25- replacing the delivery line, 6–91- vacuum meter, 6–43- visual checks, 6–15

maintenance intervals, 6–2

maintenance procedures- adjusting accumulator pressure, 6–29- checking accumulator pre--charge pressure, 6–28- replacing accumulator bladder, 6–30

measuring the wall thickness, machines with S transfertube, 6–81

module control cabinet, 3–16

Ooil cooler, troubleshooting, 7–12

open gear lubrication, 6–8

operating procedures- cable remote control setup, 5–20- cleaning the unit, 5–50- outriggers setup, 5–23- pre--operation inspection, 5–7- preliminary information, 5–2- pumping concrete with the emergency stroke kit, 5–72- radio remote control setup, 5–22- teardown, 5–65- unit setup, 5–9

output controller, emergency operation, 3–49

outriggers- description of the functions, 3–6- setup, 5–23- snaplock, 5–24, 5–69- temperature--related cylinder movements, 5–31

overview diagram, 36Z, 3–2

Ppersonnel qualifications, 2–2

piston end--of--travel positioning, KEP, 6–45

profiled ring joint, 6–6

prohibited activities, 5–27

proximity switch, 3–36- connector with LEDs, 3–38- function check, 5–3

proximity switch junction box, 3–36

pump, troubleshooting, 7–3, 7–9, 7–13

pump functions, 5–3- stroke length, 5–3- stroke time, 5–3- switchover, 5–3

pumping operations, 3–19, 5–40- agitator hopper, 5–41- blockages, 5–46- breaks in pumping, 5–45- calm pumping, 5–42

Index

IndexA–4

- cooling, 5–47- cooling, additional, 5–47- damping valve, 5–43- favorable boom position, 5–42- hand signals, 5–33- overheating, 5–47- pumping, 5–44- restarting, 5–48- starting pumping, 5–44- sucking in air, 5–41

Rradio remote control- receiver, 3–30- setup, 5–22- transmitter, 3–28- troubleshooting, 7–9, 7–12

range diagram, 36Z, 3–5

rating plate- boom, 3–4- machine, 3–3

Reaches, Extending, 2 — 7

remote control, 5–20

replacing, accumulator bladder, 6–30

retaining rope, 3–53

SS transfer tube- cleaning, 5–61- lubrication, 6–55- Replacing, 6 — 57- Wear parts, 6 — 57

safety regulations, 2–1, 2–2

service operation, 3–19

setting up, 5–7- cable remote control system, 5–20- outriggers, 5–23- radio remote control system, 5–22- unit, 5–9

setup site- calculation examples of minimum clearance from pits,5–11

- corner bearing load, 5–14- danger zone, 5–12- minimum clearance from pits, 5–9

- safe clearance from pits, 5–10- space requirement, 5–12- support block, 5–15- supporting ground, 5–13- table of timber block lengths, 5–16- timber blocks, 5–15

sinking of the boom, 5–32- cooling of the hydraulic fluid, 5–31

snaplock, outriggers, 5–24, 5–69

space requirement, 5–12

S transfer tube, measuring the wall thickness, 6–81

summary of the components, 3–2

support area, table of timber block lengths, 5–16

support block, 5–15

supporting ground, 5–13

symbols, 1–3

symbols for the control system, 3–8- boom, 3–14- concrete pump, 3–8, 3–9- electrical system, 3–11, 3–12- engine, 3–10- hydraulic system, 3–13- outriggers, 3–13

Tteardown, 5–65

technical data, 3–3- centralized lubrication system, 3–23

technical description, flushing water pump, 3–50

thunderstorms, 5–28

tightening torques- flared screwed joint, 6–6- general, 6–4

timber blocks, 5–15, 5–16

towing, 4–4

transfer tube- description of the functions, 3–7- troubleshooting, 7–6

transfer tube damping, 3–47

transmission oil, 6–8

transport position, retracting the outriggers, 5–69

travel- driving, 4–1- towing, 4–1

Index

Index A–5

TRDI 70, lubrication, 6–89

truck superstructure, cleaning, 5–64

Uuncontrolled boom movements, 5–32

Use contrary to the designated use, 2 — 5

Vvacuum meter, venting, 6–43

vibrator, 3–54

visual checks, 6–15

Wwash--out adapter, 5–53

water hose, marking, 5–55

water pump, 3–46

wind, 5–28

working range, impermissible working range, boom,5–39

manual operating & maintenance instructions bsf 36-4.12l

Documents

control system

boom control unit

boom functions control

control panel

boom filter

remote control setup

outriggers control block

hydraulic control devices