Putzmeister P 718 SD Translation Of The Original Operating Instruction Download

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Contents

Operation

6.1

Requirements

6 — 1

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6.2

Emergency shutdown procedures

6 — 2

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EMERGENCY STOP button

6 — 2

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6.3

Concrete properties

6 — 4

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Saturated mixture

6 — 4

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6.4

Filling agitator hopper

6 — 5

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6.5

Initial pumping

6 — 6

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6.6

Pumping

6 — 7

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6.7

Monitoring

6 — 8

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6.8

Blockages

6 — 9

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6.9

Breaks in pumping

6 — 10

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6.10

Drive motor

6 — 11

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6.11

Overheating

6 — 11

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Cooling unit

6 — 12

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Additional cooling

6 — 12

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Restarting

6 — 13

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6.12

Cleaning

6 — 14

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Information on cleaning

6 — 14

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Residual concrete

6 — 16

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Compressed air cleaning

6 — 16

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Cleaning preparations

6 — 17

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Catch basket

6 — 17

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Wash-out adapter

6 — 19

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T-delivery pipe with cleaning port

6 — 20

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Cement bags for high-pressure water cleaning

6 — 21

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Marking water hose

6 — 22

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Delivery line

6 — 22

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How to clean which delivery line

6 — 23

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Overview of cleaning processes for stationary delivery line 6 — 24
Suction cleaning

6 — 24

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Adjusting the wash-out sponge

6 — 25

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Summary of Contents for P 718 SD

Page 1: ...nstructions Translation of the original Operating Instructions for the machine operator and maintenance personnel to be kept near to the machine at all times Piston pump P 718 TD Machine no Rev 08 091...

Page 2: ...Putzmeister M rtelmaschinen GmbH Max Eyth Str 10 72631 Aichtal Tel 49 7127 599 0 Fax 49 7127 599 743 Service Hotline 49 7127 599 699 Mail mm pmw de Web www pmmotar de...

Page 3: ...2 3 Workplace of the machine operator 2 3 Working area 2 3 2 2 Principle 2 4 Onwards sale 2 4 2 3 Improper use and or reasonably foreseeable misuse 2 5 Safety factors 2 5 Process specific factors 2 6...

Page 4: ...d pneumatic equipment 2 24 Check 2 24 Dumping pressure 2 25 Bleeding 2 25 2 15 Place of work 2 26 Machine operator 2 26 Accessories operator 2 26 2 16 Working area 2 26 2 17 Conduct in an emergency 2...

Page 5: ...pment 3 9 Personal protective equipment 3 9 EMERGENCY STOP button 3 9 Agitator cut out 3 10 3 11 Control cabinet 3 11 3 12 Operating elements 3 13 3 13 Core pump 3 14 S transfer tube 3 14 Water box 3...

Page 6: ...4 4 Before a journey 4 2 Transport position 4 3 Lighting equipment 4 4 4 5 Towing gear 4 5 Ground clearance 4 5 Ball hitch Trailer coupling ring 4 5 Adjusting the towing gear 4 6 4 6 Parking brake 4 7...

Page 7: ...5 Hydraulic oil level 5 6 Draining condensation water 5 6 Checking the water box 5 7 Checking parts that come into contact with medium 5 8 5 2 Refuelling the machine 5 9 5 3 Test run 5 10 Starting the...

Page 8: ...ating 6 11 Cooling unit 6 12 Additional cooling 6 12 Restarting 6 13 6 12 Cleaning 6 14 Information on cleaning 6 14 Residual concrete 6 16 Compressed air cleaning 6 16 Cleaning preparations 6 17 Catc...

Page 9: ...perations 6 31 6 13 Overheating 6 32 Cooling 6 33 Additional cooling 6 33 Recommissioning 6 34 High pressure cleaner option 6 35 6 14 Using the cable remote control option 6 40 6 15 Using the radio re...

Page 10: ...21 Set screws and nuts 8 21 Maintenance Chart 40 058 Lubrication diagram for axle and wheels 8 24 40 059 Lubrication diagram 8 26 41 011 Checking acid level in the battery 8 29 44 053 Changing hydrau...

Page 11: ...fill level of centralised lubrication system 8 125 9 Decommissioning 9 1 Temporary decommissioning 9 1 Filling up the fuel tank 9 2 Antifreeze protection 9 2 9 2 Decommissioning 9 3 Location 9 3 9 3...

Page 12: ......

Page 13: ...629 Aichtal Germany Tel 49 7127 599 0 Fax 49 7127 599 743 Internet http www moertelmaschinen de E mail pmm pmw de Service hotline tel 49 7127 599 699 or the branch or services agent responsible for yo...

Page 14: ...chine Always keep the operating instructions with the machine The machine owner must make the location of these operating in structions known to all personnel charged with performing jobs on the machi...

Page 15: ...turer Modifications are made from time to time in the interests of constant improvement and may not have been taken into consideration when these operating instructions were printed If the operating i...

Page 16: ...tools required to carry out the work Normal tools i e standard tools or tools carried in the vehicle are not listed additionally Environmental protection This symbol is used to identify tasks where pa...

Page 17: ...appears in italics and is underlined The appropriate symbol will be used if it is possible to identify the source of the danger precisely Suspended Load This pictogram is used for tasks where falling...

Page 18: ......

Page 19: ...n at the appropriate points in the operating manual Notes Special safety regulations may be necessary for some tasks These special safety regulations will only be found in the description of the parti...

Page 20: ...form the following activities Operating the piston pump Simple inspection and maintenance work Testing Cleaning For the purposes of the Industrial Health and Safety Ordinance a subject expert is a per...

Page 21: ...achine Parts of the working area can become danger zones depending on the job being performed The working area is also the area where work is carried out with and on delivery lines and attached access...

Page 22: ...ssary inform the project supervisor If defects or faults are found or suspected during operation opera tion must cease immediately Eliminate the defect or fault before re starting The following should...

Page 23: ...safety equipment unauthorised or modified connections or fuses Depending on the particular model the machine is fitted with diffe rent pieces of safety equipment that serve as protection against se ve...

Page 24: ...r in the technical data Pressurised systems It is prohibited to open any pressurised systems hydraulics pneu matic system high pressure water delivery lines mixer drum etc Ensure the pressure has been...

Page 25: ...perationally safe tools must be used If the removal of safety equipment is necessary for servicing work or repairs they may only be removed for the duration of the work As soon as the servicing and or...

Page 26: ...Welding must never be performed on bearing parts pressure reser voirs fuel or oil systems etc Welding work is only authorised by explicit agreement with the ma nufacturer It must only be carried out b...

Page 27: ...r damage in the cases listed therein The manufacturer shall not be liable for damage caused by improper use and or reasonably foreseeable misuse improper operation maintenance servicing or repairs dea...

Page 28: ...do so The areas of responsibility for personnel must be clearly defined The following personnel must only work on the machine under the permanent supervision of an experienced person personnel who hav...

Page 29: ...nd after completion of work there is a danger of burns from hot parts on the drive motor The delivery hose and coupling system is designed for a max ope rating pressure of 40 bar The max operating pre...

Page 30: ...afety and accident prevention warning signs and information plates cover grilles guards etc must be in place Such equipment must not be removed modified or damaged All warning signs and information pl...

Page 31: ...Safety boots Safety boots protect your feet against falling objects and against penetration by projecting nails EN ISO 345 Safety boots for industrial purposes classification S2 Ear defenders Ear defe...

Page 32: ...ssification III Face mask and respiratory protector A face mask and respirator protector prevent particles of dust from entering your body through your respiratory passages particles such as concrete...

Page 33: ...boots Danger The machine operator must be informed that waterproof protective clothing only provides protection from spray water and splash parti cles In the case of direct contact with the high press...

Page 34: ...anger for persons working continuously in the vicinity of the machine without ear defenders Eye and skin injuries caused by escaping hydraulic fluid when threaded unions are opened without first dumpi...

Page 35: ...our Danger of crushing The machine may only be loaded by crane if fitted with suitable at tachment points Use only suitable lifting equipment for lifting components Lifting equipment lifting tackle su...

Page 36: ...ed Make sure personnel do not walk under suspended loads Only use an auxiliary loading device with a load bearing capacity designed to support the gross weight of the machine Danger If a central jack...

Page 37: ...of the skin and damage the tissue underneath The water may inject foreign matter deep into the body and cause dan gerous infections With injuries caused by high pressure water jets it is not possible...

Page 38: ...e hoses after operating the ma chine Do not crush high pressure hoses or guide them over sharp ed ges Avoid tensile and bending stress High pressure hoses must be stored free of kinks and tension High...

Page 39: ...o personnel apart from the machine operator should stand within a 10 m radius of the high pressure gun When operating the high pressure gun always hold firmly with both hands Place one hand on the hig...

Page 40: ...204 Part1 or DIN 40050 IEC 144 in accordance with protec tion category IP 54 Use only original fuses with the specified amperage The electrical system can be destroyed by overrated fuses or overriding...

Page 41: ...ith compressed air There is a risk of fatal injury because the delivery line can burst Injury through the force of bursting couplings pipelines or blockages flying out of delivery lines end hose and p...

Page 42: ...s toxic and can penetrate the skin Never without protective equipment Check all lines hoses and threaded unions regularly for leaks and obvious damage Repair damage immediately Splashed fluid may caus...

Page 43: ...storage time of no more than two years For this purpose the period must be calculated from the mar king on the fitting date of manufacture of the hose Depressurize in accordance with the specific inst...

Page 44: ...eas depending on the job being performed The working area is also the area where work is carried out with and on delivery lines and attached accessories Secure the working area and affix signs clearly...

Page 45: ...e personnel with ear defen ders although this is not compulsory Wearing ear defenders for noises louder than 90 dB A is compul sory Wear your personal ear defenders Instruct your personnel always to w...

Page 46: ...he operator or the operator s authorised maintenance and repair staff is prohibited The manufacturer accepts no liability for damages caused by unau thorised interference Danger Increased risk of inju...

Page 47: ...GmbH accepts no liability for damage caused as a result of using non origi nal spare parts Safety related parts SRP are specially labelled on the spare parts sheets 3 Labelling of SRP in spare parts...

Page 48: ...r to the delivery note for a list of accessories supplied The operating company is responsible for ensuring that the correct accessories are used Putzmeister M rtelmaschinen GmbH declines all responsi...

Page 49: ...d starting before lea ving the work area This means Switch off the pump drive and motor Switch the main switch to OFF Secure the control cabinet against opening with a lock Close the hoods The operato...

Page 50: ......

Page 51: ...will make it much easier for us to answer any questions or re spond to orders if you can give us the details of the machine model and the machine number The following data can be found on the rating p...

Page 52: ...ne models and versions from the P 718 series Machine model Versions P 718 TD Trailer machine with diesel engine P 718 TE Trailer machine with electric drive motor P 718 SD Stationary machine with dies...

Page 53: ...includes the available machine models and the va rious versions with a diesel engine or electric motor 7 4 1 2 3 5 8 6 Illustration shows diesel version Item Designation 1 Hopper 2 Protective grille...

Page 54: ...ersion Item Designation 1 Hopper 2 Protective grille 3 Control cabinet 4 Engine 5 Hydraulic fluid reservoir 6 Trailer coupling ring 7 Support wheel 8 Fuel tank filler neck 9 Support leg with support f...

Page 55: ...gth 4503 mm 3025 mm Width 1600 mm 1270 mm Height 1775 mm 1559 mm Filling height 1331 mm 1120 mm Weights Weight empty 2400 kg 2000 kg 1940 kg Permitted gross weight See rating plate Permitted drawbar l...

Page 56: ...ll side 25 min Conveyed medium max grain size 32 mm fine concrete anhydrite screed Conveyed media cement screed Conveyed media cementite screed self levelling floor screed Inclination angle in lon git...

Page 57: ...D P 718 SE Fluid capacities Engine oil Engine oil volume 6 l with filter change Engine oil volume 6 l with filter change Fuel Diesel fuel capacity approx 55 l Diesel fuel capacity approx 55 l Hydrauli...

Page 58: ...l 2 Year of manufacture 3 Maximum delivery pressure bar 4 Hydraulic pressure bar maximum fluid pressure in the hydraulic system 5 Voltage V 6 Frequency Hz 7 Power kW 8 Licence number 9 Chassis number...

Page 59: ...C the sound power level emit ted by the machine is given below Next to the rating plate on the machine there is the plate shown in the picture below which gives the machine s sound power level mea sur...

Page 60: ...ealer or local Putzmeister M rtelmaschinen GmbH re presentative as to how and whether you should upgrade your ma chine Notes Please refer to the current catalogue from Putzmeister M rtelmaschinen GmbH...

Page 61: ...ine for their own safety Any damaged parts of the personal protective equipment must be replaced immediately Notes Personal protective equipment can be purchased through the Parts Sales department of...

Page 62: ...manually operating the switch on valve and switchover valve at the fully hy draulic control block Danger The hood must be closed during machine operation in order to pre vent anyone activating the pum...

Page 63: ...rvision and guidance of a qualified electrician in accor dance with the electrical engineering rules and regulations The control cabinet s wiring earthing and connections comply with VDE codes of prac...

Page 64: ...tral lubrication system 6 Flip switch optional Vibrator ON 7 Toggle switch Electric motor OFF 8 Toggle switch Electric motor ON 9 EMERGENCY STOP button Switches off the machine in an emergency 10 Indi...

Page 65: ...control 3 4 2 5 6 1 Different models available Item Designation 1 Control cabinet under flap 2 Manual throttle lever 3 Bracket for cable remote control depending on model 4 Delivery rate controller 5...

Page 66: ...ds 1 of the drive cylinder The drive cylinders are moved in and out hydraulically pushing the delivery pistons 3 in the delivery cylinder 4 back and forward The drive cylinders are hydraulically coupl...

Page 67: ...orces the medium which has previously been sucked in through the transfer tube into the delivery line At the end of the stroke the pump switches over i e the transfer tube is swung in front of the ful...

Page 68: ...c motor 2 Mixer shaft 3 Mixer paddles During pumping the fill level in the delivery cylinders should be as high as possible This is achieved by a mixing direction of the mixing paddles to the delivery...

Page 69: ...powered by a 3 cylinder diesel engine or an elec tric motor 5 3 1 6 4 2 7 Different models available Item Designation 1 Drive motor 2 Oil filler 3 Oil dipstick 4 Fuel filter 5 Engine oil filter 6 Oil...

Page 70: ...ulic pump The drive motor 1 has different performance values depending on the model Refer to the rating plate or the chapter General technical descrip tion section Technical data for drive motor value...

Page 71: ...drives the drive cylinders of the machine The drive motor drives the hydraulic pumps of the machine which are connected to the machine by hydraulic hoses The hydraulic pumps generate the necessary oi...

Page 72: ...on of travel You have to open the hood to reach the pressure calibrator 1 2 Item Designation 1 Ball valve pressure calibrator 2 Function label 40 or 70 bar If an air chamber or delivery lines are inst...

Page 73: ...2 Pos Designation 1 Cable remote control 2 Interface cable 3 Connector The socket for the interface cable is located under the control cabi net 1 3 2 Pos Operating control elements Function display 1...

Page 74: ...ket for the interface cable is located under the control cabi net The charger is located in the toolbox under the hood This is where the discharged battery is inserted and charged The cable on the cha...

Page 75: ...ttery voltage decreases a wire breaks the radio remote con trol switches off or radio contact is interrupted the EMERGENCY STOP is activated The EMERGENCY STOP can only be acknowledged if the radio re...

Page 76: ...tted with a vibrator as an option 1 2 3 Item Designation 1 Vibrator 2 Vibrator cable 3 Grille The vibrator mounted on the grille is connected to the socket provi ded on the machine The vibrator is swi...

Page 77: ...leaner must never be operated without water Make sure that the water inlet is connected correctly Notes The high pressure cleaner is not a suction pump It must be connected to the mains water supply T...

Page 78: ...ontrol range of the high pressure cleaner is from 5 to 140 bar and depends on the number of engine revolutions The pressure can be regulated by turning the handwheel There is a trigger safety device o...

Page 79: ...e installed as an option The flushing water pump is used to wash the outside of the machine with pressurised water The flushing water pump is on the right side of the engine compart ment in direction...

Page 80: ...surised water hose connection 2 Flushing water pump pressure gauge 3 Switching valve At the switching valve in the engine compartment you can select between operation of the flushing water pump or the...

Page 81: ...cation pump conveys lubri cant from the grease distributor to the connected lubrication points during the lubrication period The pressure limiting valve limits the build up of pressure in the lubri ca...

Page 82: ...min 40 mm2 s Check the fill level in the centralised lubrication system on a daily basis and fill up the grease distributor as required Maintenance chart Checking fill level of centralised lubrication...

Page 83: ...be filled If a centralised lubrication system or lubrication circuit fault is pen ding the indicator lamp flashes with longer intervals The fault must be rectified Press the button 1 to activate the...

Page 84: ......

Page 85: ...zmeister trailer machines may only use public roads if properly approved They are subject to Road Traffic laws when being towed in road traffic This also stipulates the maximum permissible road speed...

Page 86: ...enly at all support points Suspended Load Personnel should never walk or stand under suspended loads Only use an auxiliary loading device with a loadbearing capacity de signed to support the gross wei...

Page 87: ...hine is fitted with runners with integral slots for accommoda ting the fork on a fork lift truck You can insert the truck fork here to lift the machine Insertion slots for the forks on fork lift truck...

Page 88: ...able if fitted is secured to the towing vehicle The support wheel if fitted is raised and secured once the trailer has been attached All support feet if fitted are raised and secured once the trailer...

Page 89: ...nt is installed on the machine and connected The hood is closed tightly The hopper is empty The hopper grill is closed The remote control if fitted is unplugged and stored safely All required attachme...

Page 90: ...n 1 Lighting equipment 2 Power cable 3 Connector The lighting equipment 1 on which the vehicle registration plate is located next to the lighting must be inserted in the mounting eyes on the rear of t...

Page 91: ...en being towed by the trac tor unit The trailer coupling ring ball hitch must be inserted attached hori zontally to the trailer coupling on the towing vehicle The chassis is designed for transportatio...

Page 92: ...2 Release the locking toggle and turn it as far as the stop The towing gear 1 can now be adjusted upwards and downwards to the stops M20x1 5 M28x1 5 M36x1 5 Tightening torque MA 250 Nm 400 Nm 650 Nm L...

Page 93: ...lls backwards the gas filled spring automatically clamps the wheel brake Caution Always pull the brake lever over the dead centre position with force The machine must be secured additionally with choc...

Page 94: ...Caution In normal driving mode under no circumstances must there be ten sion on the brake safety cable when the trailer is attached The brake safety cable must not be completely taut even when tra ve...

Page 95: ...over with a red green red label with the same symbols and a pointer 2 1 3 Item Designation 1 Ball hitch 2 Hitch handle 3 Display Danger The trailer can only be driven if correctly coupled After the b...

Page 96: ...n Green symbol The ball hitch is locked correctly Notes After connection you should always check the indicator to see whe ther the ball hitch is engaged correctly on the ball If the indicator is withi...

Page 97: ...out risk of accidents Have worn parts repla ced immediately The swivel range of the ball hitch around the vehicle longitudinal axis is max 25 Horizontally slewing angles within a range of 20 are poss...

Page 98: ...he towing vehicle and the trailer A B C Coupling the ball hitch Open the ball hitch by pulling the hitch handle upwards A The ball hitch stays in the open position in which the indi cator points at th...

Page 99: ...trailer can separate from the towing vehicle and cause an accident If the indicator is in the red area then the ball hitch is not connec ted properly and the trailer must not be driven under any circu...

Page 100: ...y pulling the hitch handle upwards The ball hitch stays in the open position in which the indi cator points at the red area with the large X Danger The trailer must never be driven in this condition L...

Page 101: ...ne is accessible from all sides for servicing and repairs Caution The machine be situated outside the danger zone of elevated work sites or protective roofing must be provided for the machine at its o...

Page 102: ...th detachable lighting equipment fit this equipment to the bracket provided before operating the machine Observe the maximum inclination angles during machine set up and operation Refer also to chapte...

Page 103: ...the machine is horizontal Pull out the spring pin 3 Hold the support leg 1 firmly in position while pulling out the locking pin 2 Lower the support foot At the same time align the bore for the lock p...

Page 104: ...nection must be made on the basis of the electrical circuit diagram supplied The electrical circuit diagram can be found in the machine spare parts list Caution Do not turn the main switch on at this...

Page 105: ...f the electrical con nection has not been properly made or the supply cable is dama ged The machine must be connected to a separate feed point at the con struction site The following power sources are...

Page 106: ......

Page 107: ...al operation Every time the machine is in operation the operator accepts full re sponsibility for the safety of anyone located in the machine s danger zone He is therefore obliged to ensure absolute o...

Page 108: ...ttachment are clo sed Check the most important wear parts Check the fill levels of the operating materials Refer also to section Operating materials Check that all closures are correctly sealed Check...

Page 109: ...nd always take note of the ma nufacturer s information Caution Putzmeister accepts no liability for damage resulting from the use of unauthorised operating materials The documentation provided by the...

Page 110: ...chapter Starting up section Filling the machine with fuel Check the engine oil level of the drive motor as follows Withdraw the oil dipstick of the drive motor wipe the dipstick with a lint free cloth...

Page 111: ...are contaminated Maintenance chart Cleaning the radiator Check the fill level of the centralised lubrication system as follows Maintenance chart Checking fill level of centralised lubrication system T...

Page 112: ...Use only the hydraulic oils specified in the lubricant recom mendation For fluid capacities refer also to chapter General Technical Des cription section Technical data Caution The capacities are only...

Page 113: ...originate from the dry run lock on the delivery piston Only if oil is clearly escaping are the drive cy linders leaking Caution The hydraulic oil is also cooled by the water in the water box The hydr...

Page 114: ...ck the inner wall of the tube and the thrust ring for wear Maintenance chart Discharge connection and S transfer tube bearing Look into the hopper and check the condition of the specta cle wear plate...

Page 115: ...herwise become damaged When filling the machine with fuel pay particular attention to cleanli ness Danger Fill the machine with fuel only when the engine is not running Smoking is absolutely prohibite...

Page 116: ...osing the hood the hood interlock must audibly engage The hood must also be secured with the lock and the key removed Do not exceed the motor speed specified in the Technical data section Always set t...

Page 117: ...net under flap 2 Manual throttle lever 3 Delivery rate controller 4 Mixer lever Agitator PUMPING 0 MIXING Set the delivery rate controller to min Set the Agitator PUMPING 0 MIXING mixer lever to neutr...

Page 118: ...lamp lights up Switch the Pump ON 0 Reverse pumping ON toggle switch to the 0 position Switch the Local 0 Remote toggle switch to the Local po sition Start the drive motor by turning the ignition star...

Page 119: ...for service 0 Manual throttle to slightly above idling Set the manual throttle to slightly above the min mark Caution Always set the motor to above the speed where it begins to shake 500 700 rpm This...

Page 120: ...rk Caution Always set the motor to above the speed where it begins to shake 500 700 rpm This prevents unnecessary mechanical load on the machine caused by vibrations Switch the Pump ON 0 Reverse pumpi...

Page 121: ...s rotate towards the delivery cylinder Set the Agitator PUMPING 0 MIXING mixer lever to MI XING The agitator is switched on The mixing paddles rotate away from the delivery cylinder Notes The machine...

Page 122: ...imum speed Calibrate the quantity to ma ximum Measure the stroke time over 10 individual strokes The mea sured value divided by 10 must correspond to the specifications in the measurements sheet Check...

Page 123: ...50 C Set the output controller to the maximum output Notes The contamination indicator of the reverse fine filter can only be checked under load and when the hydraulic oil is warm 1 2 Item Designatio...

Page 124: ...service temperature has been reached If necessary press the red button of the contamination indica tor back in Check the optical contamination indicator Notes If the red button on the optical contami...

Page 125: ...TOP button in the event of danger Do not use the EMERGENCY STOP button to switch off the machine Press Lock EMERGENCY STOP button Turn Unlock EMERGENCY STOP button Start the engine See also the Starti...

Page 126: ...ut Caution The machine is no longer safe to operate if the EMERGENCY STOP button is defective as you will no longer be able to switch off the ma chine quickly enough in the event of potential danger I...

Page 127: ...drive motor Switch on the agitator Refer also to the section Switching on the agitator cut out 1 2 Different models available Item Designation 1 Agitator grill 2 Limit switch Notes The safety device...

Page 128: ...Hopper attachment 2 Limit switch Notes The safety device at the hopper attachment 1 is equipped with a limit switch 2 which switches off the agitator as soon as the hopper attachment is raised Raise...

Page 129: ...luing You must ensure that you use a seal which is designed for the purpose to secure any new coupling against being opened You must screw the coupling to the stop After this it should no longer be po...

Page 130: ...tion 1 Toggle switch Pump ON 0 Reverse pumping ON 2 Output controller Control reduction of the output controller 2 The pump comes to a halt Switch the pump off at toggle switch Pump ON 0 Reverse pumpi...

Page 131: ...ling the machine Before you fill material into the machine and pump it through the delivery line you must be sure that the machine functions correctly the delivery line is designed to withstand the in...

Page 132: ...gency occurs while you are operating the machine The control cabinet of the machine is fitted with an EMERGENCY STOP button Caution Familiarise yourself with the position of the EMERGENCY STOP but ton...

Page 133: ...accordance with company pro cedures Look for the cause of the fault and have it rectified rectify it completely Unlock the EMERGENCY STOP button by turning it Notes To cancel the EMERGENCY STOP status...

Page 134: ...ency of the pump i e the concrete delivery rate per stroke 1 2 3 Item Designation 1 Aggregate 2 Cement paste 3 Boundary layer Notes A lower fill level will be achieved in the delivery cylinder if the...

Page 135: ...very line is dangerous since the compressed air is expelled suddenly from the end of the delivery line and the me dium can be ejected explosively No air must be sucked in for this reason You should th...

Page 136: ...n the entire delivery pipe has to be wetted Introduce the 2 sponge balls into the delivery line Fill approx 250 litres low viscosity concrete into the hopper Switch the agitator on Pump the medium slo...

Page 137: ...mixture continue mixing after their addition for at least 4 minu tes Pour the concrete from the truck mixer silo etc into the agita tor hopper Switch the agitator on Start pumping Notes Start with a...

Page 138: ...hese checks at regular frequent intervals all the time the machine is in operation Danger The machine must be switched off every time a fault is displayed All faults must be eliminated immediately oth...

Page 139: ...es are not seal tight Residual concrete in transfer tube and delivery line Unfavourable concrete composition Demixed concrete Set concrete Caution In the event of blockages pump the concrete immediate...

Page 140: ...power ten dency to bleed you should avoid interruptions because vibrations can demix the medium When you restart delivery it is essential to continue reverse pumping until the transfer tube has fully...

Page 141: ...high ambient temperatures too little fluid in the hydraulic system contaminated radiator grille inadequate radiator supply exhaust air radiator draws in hot exhaust gases excess pressure as a result...

Page 142: ...If these measures are insufficient in case of emergency you can cool the drive cylinder with a water jet 10600400 Direct the water jet at the drive cylinder and piston rods of the drive cylinder Caut...

Page 143: ...e hydraulic fluid radiator must re main in operation Refresh the water in the water box Wait until the hydraulic fluid has cooled if you are not able to find the fault immediately When the red pilot l...

Page 144: ...tion The machine must only be cleaned on the outside with a steam jet high pressure cleaner The hood must remain closed Notes In the first four operating weeks clean all painted surfaces with cold wat...

Page 145: ...regulations that apply to your region Cleaning additives or diesel fuel must not be permitted to enter the sewage system Water which sprays the machine from all directions does not have any damaging...

Page 146: ...g site crane Danger During all cleaning operations keep the agitator grille closed be cause it can be struck by the agitator Do not reach into the hopper Compressed air cleaning Danger When cleaning w...

Page 147: ...ssed air It must be designed so that the medium can flow out unhindered however the sponge ball cube scraper must be collected and the delivery line thereby sealed at the same time to the rear Danger...

Page 148: ...Operation 6 18 05_0010_0507GB 1 2 3 4 Item Designation 1 Coupling 2 Catch basket closed pipe segment 3 Spring pin on two sides 4 Catch bracket Continuation next side...

Page 149: ...sed for cleaning with pressurised water or compressed air up to 10 bar When pressing out the concrete with compressed air the catch bas ket at the end of the delivery line is compulsory otherwise ther...

Page 150: ...leaning it is used to catch the wash out sponge 1 2 Item Designation 1 T delivery pipe with cleaning port 2 Wash out port lid Danger When using the T delivery pipe also ensure that it is designed for...

Page 151: ...penetrating the cement and flushing it out causing blockages Rolled up cement bags Roll up 1 2 empty cement bag Prior to cleaning immerse the rolled up cement bags for ap prox 5 minutes in water Note...

Page 152: ...ry through the transfer tube as it switches 1 Item Designation 1 Adhesive tape marking Measure the required hose length on the outside of the transfer tube The spray nozzle of the hose should be posit...

Page 153: ...verse direction from the site of concrete placement to the hopper The delivery line was separated from the concrete pump The residual concrete is pressed forwards by an external force compressed air o...

Page 154: ...al Downpipe Pressurised water special equipment Suction cleaning Suction cleaning is the simplest and safest method of cleaning of a riser It is described below Pump the agitator hopper empty up to th...

Page 155: ...otes If there is concrete in the delivery line tapping produces deep thud ding sounds As soon as the concrete and wash out sponge have passed the tapping point the tapping produces high clear sounds T...

Page 156: ...the wash out port lid and remove the wash out sponge Repeat the cleaning process because single reverse pumping with the wash out sponge is not sufficient High pressure water cleaning which is more t...

Page 157: ...er Switch the pump to Forward pumping The medium in the delivery pipe is pushed out with the aid of the water to the end of the delivery line Refill the hopper with water in good time for long deliver...

Page 158: ...tube and damaged Personal injury is also possible through the uncontrolled movement of objects Place a sheet underneath Position a suitable foil under the hopper Open the hopper flap at the bottom of...

Page 159: ...nection and working downwards Insert the hose slowly up to the marking see Chapter Marking water hose Insert the water hose up to the marking in the transfer tube Hold the water hose inserted up to th...

Page 160: ...n transfer tube and wear ring The gap S must be 1 5 to 2 mm otherwise the transfer tube must be readjusted Maintenance chart Adjusting S transfer tube S 2 3 4 1 Item Designation 1 S transfer tube 2 Th...

Page 161: ...ing long pumping inter ruptions e g overnight and at weekends etc Afterwards leave the water outlet open Danger Atomised preserving agents are highly explosive When spraying keep away from all ignitio...

Page 162: ...n the en gine type Excess pressure caused by blockages Insufficient water in the water box All pumps have a thermoelectric cutoff The pump is switched off au tomatically if the oil overheats to above...

Page 163: ...ration If the measures mentioned up to now are ineffective you can cool the drive cylinder with a water jet as a last resort 10600400 Direct the water jet at the drive cylinder and piston rods on the...

Page 164: ...x Wait until the hydraulic oil has cooled down Switch off the machine Refer also to chapter Starting up section Shutting down the machine after operation Pinpoint the cause of overheating of the hydra...

Page 165: ...ines of the danger area when performing work involving high pressure water jets No personnel apart from the machine operator should stand within a 10 m radius of the high pres sure gun When operating...

Page 166: ...water or other non aggressive or abrasive media with a similar specific weight to water Start up high pressure cleaner operation as follows 1 2 3 4 5 Different models available Pos Bezeichnung 1 High...

Page 167: ...high pressure cleaner is not a suction pump It must be connected to the mains water supply The available water pressure must be at least 0 5 bar Open the hood Danger Never reach into moving machine co...

Page 168: ...to the chapter Starting up section Starting the drive motor Actuate the high pressure gun trigger The operating pressure can be read off at the pressure gauge 3 If necessary regulate the operating pr...

Page 169: ...position Close the hood again Close the water supply Press the high pressure gun trigger to relieve the pressure The residual pressure in the hose and high pressure gun is relieved Caution The machin...

Page 170: ...able remote control 3 1 2 Item Designation 1 Cable remote control 2 Interface cable 3 Connector The socket for the interface cable is located under the control cabi net Insert the connector on the int...

Page 171: ...tch to the Remote position The Fault indicator lamp lights up 1 3 2 Item Designation 1 Acknowledge emergency stop toggle switch 2 Pump ON 0 Reverse pumping ON toggle switch 3 EMERGENCY STOP button Act...

Page 172: ...f a battery depends entirely on the age of the battery and the ambient temperature The capacity of older batteries de creases over time The capacity of a battery decreases more rapidly at temperatures...

Page 173: ...t Notes The transmitter is fitted with the electronic radiomatic master key The radiomatic master key contains all the data required to operate the transmitter The machine cannot be operated without t...

Page 174: ...ced Otherwise the transmitter will switch off after a few minutes Always recharge the battery using the charger provided The socket for the interface cable is located on the frame below the control ca...

Page 175: ...radio remote control must be switched off when changing loca tion performing tasks that do not require a radio remote control ta king work breaks and at the end of a job Press the stop button Danger...

Page 176: ...trols so that they can be reset and then press the start button The machine should now respond to radio commands The reset process was de signed to prevent the machine from making uncontrolled movemen...

Page 177: ...p Switch the Local 0 Remote flip switch to the Local posi tion The Fault indicator lamp lights up Actuate the toggle switch Acknowledge EMERGENCY STOP The Fault indicator lamp goes out Operate the mac...

Page 178: ......

Page 179: ...erve the safety regulations when searching for a fault Danger Work on the electrical and hydraulic equipment of the machine must be carried out by a qualified electrician a hydraulic technician or by...

Page 180: ...ixer grille and hopper attachment closed At the control valve of the main pump the LED voltage present lights up at the plug socket Voltage present at the control valve of the main pump Check whether...

Page 181: ...er Check setting dimension replace worn parts and adjust Setting values can be obtained from your service dealer No sequential signal from the HCV valves Check HCV valves for correct movement Transfer...

Page 182: ...rate not reached Cause Remedy Stand by pressure too low Set stand by pressure in accordance with specifications Setting work must be carried out by the service dealer Output controller setting too low...

Page 183: ...valve of P connection to control connection x or y Replace main valve Transfer tube switches slowly at low delivery rate Cause Remedy Shuttle valve 197 defective Check shuttle valve replace if necess...

Page 184: ...too hot Replace with cold fresh water Too little fluid in the hydraulic system Top up hydraulic fluid Pump is running in the maxi mum pressure range because of poor concrete and a high delivery rate...

Page 185: ...ing instructions Notes Consult a service engineer from Putzmeister M rtelmaschinen GmbH or a dealer authorised by Putzmeister M rtelmaschinen GmbH if you cannot rectify the fault by yourself Refer als...

Page 186: ...play incorrect Have checked and adjusted Injection valve defective Have replaced The drive motor runs erratically or stops completely Cause Remedy Insufficient fuel in the tank Add fuel Fuel filter d...

Page 187: ...clogged Clean the fuel filter replace if necessary Incorrect fuel Replace with the correct fuel Dry air filter dirty Clean filter element replace if necessary Dry air filter maintenance indicator def...

Page 188: ...Cause Remedy Inclination angle of machine excessive Align machine horizontally Engine oil level excessive Reduce engine oil level The drive motor is smouldering white Cause Remedy Ambient temperature...

Page 189: ...Dry air filter dirty Clean filter element replace if necessary Dry air filter maintenance indi cator defective Have checked and repaired Charge air duct leaking Have checked and repaired Valve play i...

Page 190: ...qualified electrician and in accordance with electrical engineering rules and regulations Pump is switch on but does not start Cause Remedy Delivery rate too low Increase output The red Fluid overheat...

Page 191: ...nder gasket defective switches an inductive switch is defective A coil at the switchover valve is defective Replace switchover valve Check valve at the full hydraulic control block is defective Connec...

Page 192: ...hop One sided braking effect Cause Remedy Wheel brake operation is one sided Have checked and set by specialist workshop Trailer brakes when accelerator pedal of tractor unit is released Cause Remedy...

Page 193: ...ave checked set corrected by specialist workshop Spring brake is already pre loaded in zero position Have checked and set by specialist workshop Handbrake lever was not or only partly released Move ha...

Page 194: ...ance of a qualified electrician and in accordance with the electrical engineering rules and regulations Notes Consult the relevant service department at Putzmeister M rtelma schinen GmbH if you cannot...

Page 195: ...ks correctly Check the function of the transmitter using a fully charged or spare battery The status LED in the transmitter flashes green but it is impossible to execute control commands Cause Remedy...

Page 196: ......

Page 197: ...enance charts necessary for this machine A summary of the maintenance charts listed by number is included in the table of con tents We should like here to emphasise expressly that all prescribed check...

Page 198: ...appropriate for mat Inspection and maintenance personnel performing maintenance and inspection work on behalf of the machine operator must be tech nically qualified and authorised Appointed personnel...

Page 199: ...ngly Notes For the maintenance work intervals and performance please also refer to the documentation provided by the engine manufacturer Use only original spare parts Putzmeister M rtelmaschinen GmbH...

Page 200: ...years other intervals Reference General machine Visual inspection defects and leaks rectify defects seal leaks Measure stroke time have repaired if necessary Section Function checks Electrical cablin...

Page 201: ...fety equipment EMERGENCY STOP button fully functional have repaired if necessary Section Function check of the EMERGENCY STOP button Agitator cut out fully functional have repaired if necessary Sectio...

Page 202: ...y MC 44 127 Clean the dry air filter dust discharge valve weekly MC 44 127 Check fuel level top up if necessary Section Filling the machine with fuel Fuel filter MC 44 140 Fuel line filter MC 44 140 D...

Page 203: ...ter 100 h Action daily Drive motor Check the engine mount replace if necessary 12000 h Service Check engine monitor repair if necessary Service Crankcase vent valve 3000 h Service Check and adjust inj...

Page 204: ...r box check secur ing wire on spacer flange repair if necessary Section Checks MC 46 022 Water box check that the screws on the spacer flange are seated correctly tighten if necessary Section General...

Page 205: ...rod check for leaks and wear have replaced if necessary Service Switch lever check that the clamping bolts are seated correctly tighten if necessary Section General tightening torques S transfer tube...

Page 206: ...y 6 years MC 44 062 Visual check leaks MC 44 062 Check the hydraulic oil level top up if necessary Section Checks Hydraulic oil reservoir drain condensation if necessary weekly Section Checks Hydrauli...

Page 207: ...ction if there is a risk of freez ing MC 52 006 Flushing water pump option Flushing water pump antifreeze protection if there is a risk of freez ing MC 52 007 Centralised lubrication system option Che...

Page 208: ...apter is also required Maintenance inspection and repair work may only be carried out by specialist personnel Personnel must have successfully completed a specialist training course that qualifies the...

Page 209: ...he manufacturer of the operating materials Danger Risk of burns due to hot operating materials and surfaces e g en gine radiator and frame Allow hot operating materials and surfaces to cool first Alwa...

Page 210: ...heel bearings Service Check the wheel bear ings adjust the play if necessary after the first 500 km Service Check that the fastening bolts are seated correctly tighten if necessary after the first 500...

Page 211: ...are seated correctly tighten if necessary Service Ball hitch check play repair if necessary 20000 km Service Lubricate the towing gear 6 months as required Section Lubrication diagram Clean the towin...

Page 212: ...Check that the parking brake is fully functional moves easily adjust if necessary Service Parking brake check gas filled spring for leaks have repaired if necess ary Parking brake check gas filled sp...

Page 213: ...from other wa ste Comply with the relevant national and regional regulations Only work with waste disposal companies who are approved by the responsible authorities You must keep used oils of various...

Page 214: ...hen the engine is not running Smoking is absolutely prohibited when refuelling Never fill the fuel tank near naked flames or ignitable sparks Ensure that fuel does not spill onto hot machine component...

Page 215: ...e Notes Please refer to the documentation provided by the engine manufac turer for specifications regarding approved operating materials and the necessary fluid capacities See also the documentation p...

Page 216: ...y multi purpose grease with a lithium soap base in accordance with the lu bricant recommendation Lubricate the axle and wheels at least once a year using a high qua lity multipurpose grease in accorda...

Page 217: ...be replaced after removal The maximum tightening torques for set screws and nuts can be found in the spare parts list for your machine Notes The tables contains the maximum tightening torques MA in N...

Page 218: ......

Page 219: ...8 23 07_0109_1201GB Maintenance charts The following section contains the necessary maintenance charts for this machine A summary of the maintenance charts listed by number is included in the table o...

Page 220: ...s a particular risk of accident Therefore always read the chapter Safety regulations and the description Other risks during maintenance work at the be ginning of the Maintenance chapter No further mai...

Page 221: ...tenance Chart 8 25 WK40_058_1301GB Different models available Item Designation 1 Guide bearing front 2 Guide bearing rear 3 Support wheel bearing bushing upper if available 4 Support wheel bearing bus...

Page 222: ...further maintenance charts required The following special tool is required Grease gun Notes Use only lubricants specified in the lubricant recommendation table The specified lubrication interval appli...

Page 223: ...r also to chapter Starting up sec tion Switching on the agitator Notes Lubricate the mixed shaft bearings only when the agitator is running Switch the pump on Refer also to chapter Starting up sec tio...

Page 224: ...Electric motor fan cover if available 2 B Piston rod switch cylinder left Piston rod switch cylinder right Switching shaft S transfer tube bearing 3 C Switch cylinder housing left Switch cylinder hous...

Page 225: ...dent Therefore always read the chapter Safety regulations and the description Other risks during maintenance work at the be ginning of the Maintenance chapter Danger The gases given off by the battery...

Page 226: ...ation 1 Battery 2 Minimum maximum mark 3 Cap on battery cell Check the acid level at the minimum maximum mark To fill with distilled water proceed as follows Open each battery cell and fill with disti...

Page 227: ...enance charts Changing hydraulic fluid filter Cleaning hydraulic fluid radiator Checking and replacing hydraulic hoses No special tools required Caution Work on hydraulic equipment may only be carried...

Page 228: ...them before chan ging oil Never leave the tank lid open for longer than necessary The following steps describe how to change the hydraulic fluid 1 6 1 4 1 5 1 3 1 2 1 1 Item Designation 1 Oil filler...

Page 229: ...calding from hot hydraulic fluid Open the oil drain cock carefully and allow the used oil to drain into the oil catch pan You can also turn the filler slightly so that the hydraulic fluid drains more...

Page 230: ...Maximum mark in the fill level indi cator Use only the hydraulic fluids specified in the lubricant recom mendation Fill the hydraulic fluid reservoir again fluid capacity ap prox 45 l Check the hydrau...

Page 231: ...tools required Notes The flow rate of filter inserts freely available on the market is insuffi cient You must therefore only ever use original Putzmeister filter inserts in order to prevent damage to...

Page 232: ...Reverse fine filter 2 Maintenance flap Replace the filter insert on the reverse fine filter if the red button on the visual contamination indicator pops out Notes When switching on the machine the re...

Page 233: ...e hydraulic fil ter Environmental protection Always take care when collecting the old hydraulic fluid Guard against spillages Separate the collected hydraulic fluid and the used filter inserts from ot...

Page 234: ...ome clogged again Clean the filter casing thoroughly with a suitable fluid e g petroleum ether paraffin Caution Before you fit the new filters you must check all O rings and other seals on the filter...

Page 235: ...ctions in a series of test runs and check the hydraulic system for leaks The reverse coarse filter is located in the engine compartment under the hood Reverse coarse filter inside the engine compartme...

Page 236: ...uid from the filter casing into the pan Remove the filter insert Dispose of the old filter insert and the drained hydraulic fluid in accordance with local specifications Caution You must never attempt...

Page 237: ...r insert Screw the filter casing back onto the filter head by hand Use the tool again to screw the retaining bracket back onto the filter casing Bleed the hydraulic system carefully Check the hydrauli...

Page 238: ...ginning of the Maintenance chapter Caution Work on hydraulic equipment may only be carried out by persons with special knowledge and experience in hydraulic systems who can provide appropriate certif...

Page 239: ...e the hydraulic hoses at the slightest sign of damage or even a mere indication threatening damage Dark and moist patches on the fitting are external signs of incipient damage Check the hydraulic hose...

Page 240: ...permitted tightening torque Tighten the threaded union until you clearly feel an increase in the force required if you do not have a torque wrench available You must replace these flared screwed joint...

Page 241: ...y collect escaping hydraulic fluid without fail and dispose of in accordance with regulations Guard against oil spillage Biologi cally degradable hydraulic fluids must also be disposed of separa tely...

Page 242: ...ome blocked Never leave the reservoir lid open longer than ne cessary Make sure the hydraulic hoses are kept free of dirt at all times Fit the new hydraulic hoses without kinks or friction points Note...

Page 243: ...afety regulations and the description Other risks during maintenance work at the be ginning of the Maintenance chapter Refer also to the maintenance charts General maintenance work The following speci...

Page 244: ...nts in accordance with current applicable regulations Comply with the relevant national and regional regulations Only work with waste disposal companies who are approved by the responsi ble authoritie...

Page 245: ...e the oil drain hose Notes Please refer to the documentation of the engine manufacturer for specifications on the tightening torques the permissible lubricants and the necessary filling quantities Cha...

Page 246: ...Starting the engine Allow the engine to run for approximately 2 minutes checking for leaks from the oil drain plug and engine oil filter Check the engine oil pressure at the Engine oil pressure si gn...

Page 247: ...ntenance inspection and servicing work poses a particular risk of accident Therefore always read the chapter Safety regulations and the description Other risks during maintenance work at the be ginnin...

Page 248: ...Pull the filter element carefully from the filter casing Avoid disturbing dust where possible Notes Never clean with oil petrol or other flammable liquids or solvents Clean the inside of the filter c...

Page 249: ...nt must not be damaged A suitable distance must be maintai ned between hose nozzle and filter element Record the cleaning date on the filter element so that you have documentation of the number of cle...

Page 250: ...direction of the arrow Clean the discharge slot Remove any encrusted dust by pressing the area around the top of the valve 1 2 Item Designation 1 Maintenance indicator 2 Reset button for maintenance...

Page 251: ...spection and servicing work poses a particular risk of accident Therefore always read the chapter Safety regulations and the description Other risks during maintenance work at the be ginning of the Ma...

Page 252: ...aution Prior to cleaning with water or other cleaning agents cover or seal all openings which water or cleaning agents must not penetrate for safety or operating reasons Electric motors and switch cab...

Page 253: ...leaner can be used You may use a paint brush or soft brush in addition to the water jet if the dirt is difficult to shift Please also ensure that the cooling fins are not damaged while do ing this Spr...

Page 254: ...read the chapter Safety regulations and the description Other risks during maintenance work at the be ginning of the Maintenance chapter No special tools required Notes See also the engine manufacture...

Page 255: ...tension Check the V belt tension by pressing with your thumb The V belt must be retightened if it can be pressed in more than 8 mm Have the V belt tightened or replaced if necessary Check the V belt...

Page 256: ...not been used for lon ger periods 1 or more days You will find the maintenance intervals in the maintenance summary at the start of this chapter Notes Maintenance inspection and servicing work poses...

Page 257: ...Fuel pump 4 Oil filler Vent the fuel line as follows Fill the machine with fuel Refer also to chapter Starting up section Filling the machine with fuel Actuate the hand pump 2 approx 10 times The fuel...

Page 258: ...on Other risks during maintenance work at the be ginning of the Maintenance chapter The following special tool is required Filter wrench Notes For changing the fuel filter see also the engine manufact...

Page 259: ...artridges according to regulations Comply with the relevant national and regional regulations Only work with waste disposal companies who are approved by the responsible authorities Several fuel filte...

Page 260: ...he sealing surface on the filter head 2 with a lint free cloth Lightly oil the sealing surface on the filter head and the seal on the new filter cartridge with engine oil Screw on the new oil filter c...

Page 261: ...om the hoses Collect the escaping fuel and dispose of the fuel line filter ac cording to regulations Attach the new fuel line filter to the hoses Pay attention to the flow direction Tighten the hose c...

Page 262: ...ignation 1 Fuel filter 2 Filter cartridge 3 Drain plug Drain water from the fuel filter as follows Hold a suitable container under the drain plug 3 on the fuel filter Open the drain plug and drain the...

Page 263: ...d No special tools required Caution Maintenance work must only be carried out by authorised personnel with special knowledge and experience Damage to the delivery piston must be repaired immediately P...

Page 264: ...horised starting Secure your working area and fix information signs to the lok ked controls and setting devices Proceed as follows to shut down the machine Refer also to chapter Starting up section St...

Page 265: ...ry cylinder 2 Delivery piston 3 Cover 4 Drive cylinder 5 Water box Move one of the two delivery pistons on the hopper side to its end position The spacer flange must be visible in the water box Danger...

Page 266: ...ge Put the spacer flange in a safe place to protect it from damage Screw the auxiliary screws approx 3 revolutions into the face of the delivery piston 1 Set a crowbar against the auxiliary screws and...

Page 267: ...e 7 Self locking hexagon nut Remove the hexagon head bolt 1 flange 2 and connecting piece 6 Remove the delivery piston seal 3 and guide ring 4 from the piston body 5 Check all parts of the delivery pi...

Page 268: ...s as follows You should clean and check the delivery cylinder before you install the delivery piston Caution Do not use any hard objects or corrosive cleaning agents to clean the delivery cylinder Thi...

Page 269: ...the delivery cylinder 4 thoroughly with acid free grease e g Vaseline Grease the delivery piston 3 thoroughly with acid free grease e g Vaseline Place the delivery piston by hand against the delivery...

Page 270: ...n delivery piston 1 and drive cylinder Notes Only use new lock washers for the hexagon head bolts Install the spacer flange with hexagon head bolts 4 and new lock washers 5 on the piston rod flange of...

Page 271: ...or the hexagon head bolts Install the spacer flange with hexagon head bolts 4 and new lock washers 5 on the connecting piece of the delivery piston Tighten all hexagon head bolts on the spacer flange...

Page 272: ...a particular risk of accident Therefore always read the chapter Safety regulations and the description Other risks during maintenance work at the be ginning of the Maintenance chapter No further main...

Page 273: ...suitable lifting equipment for lifting components Notes It is advisable to use belts and straps to avoid causing damage Suspend the mixer shaft on suitable lifting equipment 5 3 4 3 1 2 Item Designat...

Page 274: ...des of the mixer shaft 4 Slide the mixer shaft 4 to the side until it can be removed from the other side The following steps describe how to check and assemble the bea ring flange 6 3 2 1 7 5 4 Item D...

Page 275: ...asher Damage kinks cracks or porous surfaces on the O ring Damage or scores on the bush Mixer shaft play Damage to the flange housing Caution Damaged or worn parts must be replaced Apply grease to the...

Page 276: ...ts of the mixer shaft for wear Notes Wear parts must be replaced if wear is detected during the visual check 2 mm 4 2 3 6 1 5 7 Item Designation 1 Engine cover 2 Mixer shaft 3 Bearing flange with seal...

Page 277: ...bearing flange Caution Use only self locking hexagon nuts for this purpose Secure the hydraulic motor with the hexagon screw Screw the stop nut so that a distance of 2 mm remains between stop nut and...

Page 278: ...maintenance work at the be ginning of the Maintenance chapter Refer also to the maintenance charts Discharge connection and S transfer tube bearing Switching shaft The following special tool is requir...

Page 279: ...our face away when opening the line coupling Disconnect the delivery line Remove all necessary lubrication lines and seal them with plugs Suspended Load Use only suitable lifting equipment for lifting...

Page 280: ...way Push the S transfer tube away from the wear stay until the S transfer tube inlet is free 2 1 Item Designation 1 Wear stay 2 Fastening bolts for wear stay Secure the wear stay 1 to prevent from fal...

Page 281: ...e build up in the delivery line 1 2 3 Item Designation 1 Wear ring 2 O ring 3 S transfer tube Remove the old wear ring 1 and O ring 2 Thoroughly clean the support for the O ring Dirt and residual conc...

Page 282: ...aged or worn parts must be replaced 1 2 3 1 4 5 5 mm 6 Item Designation 1 Saucer head screw 2 Wear stay 3 Rubber washer 4 Rubber buffer 5 Self locking hexagon nut 6 Square seal Clean the installation...

Page 283: ...tally up to the wear stay At the end of maintenance work the following tasks must be car ried out Refit the switching shaft Maintenance chart Switching shaft Reinstall the S transfer tube bearing Main...

Page 284: ...work poses a particular risk of accident Therefore always read the chapter Safety regulations and the description Other risks during maintenance work at the be ginning of the Maintenance chapter Refer...

Page 285: ...machine before starting work and secure it against unauthorised or accidental starting Proceed as follows to shut down the machine Refer also to chapter Starting up section Shutting down the ma chine...

Page 286: ...ection Starting engine Set the output controller to min Set the manual throttle to the idle position Start the engine Actuate the toggle switch Acknowledge EMERGENCY STOP Accelerate using the manual t...

Page 287: ...ation 1 Retaining plate fastening bolts 2 Tighten the clamping bolts on the switch lever 3 Switching shaft 4 Switch lever 5 Adjusting nut 6 Retaining plate Remove the lubrication lines from the switch...

Page 288: ...amping screws Release the clamping screws on the switch lever Notes The gap clearance between wear ring and S transfer tube must be set to ensure that the transfer tube switches correctly S 2 3 4 1 It...

Page 289: ...he adjusting nut on the retaining plate Screw in the hexagon head bolt to secure the retaining plate and tighten to 86 Nm Tightening clamping screws Notes Use only new nuts for the clamping bolts Remo...

Page 290: ...l angle is too small 3 The swivel angle is correct You can adjust the switching overlap of the wear ring and the wear stay by placing positioning rings behind the spherical seat of each retracted swit...

Page 291: ...ts can crush body parts and cause serious injury Never reach into the machine when it is running Danger Pressurised hydraulic components may move unexpectedly and cause serious injury Check that all p...

Page 292: ...nder moved in Shut the machine down Using a felt tip pen or crayon mark the position of the wear ring on the wear stay Start the machine up Allow the other switch cylinder to retract Shut the machine...

Page 293: ...t wards The compensating disc is too thin and must be re placed by a X 2 mm thicker disc 2 The swivel angle is too small if the circle is displaced in wards The compensating disc is too thick and must...

Page 294: ...plate 2 from the extended switch cylin der 1 Removing switch cylinder Notes You can force the switch cylinders back or screw a forcing screw into the assembly bores for the ball cups and force the swi...

Page 295: ...serted in the switch lever as other wise the switch cylinder can run over the edge of the ball cup and break it Fit a thicker or thinner packing washer as required with the ball cup Fit the switch cyl...

Page 296: ...asure how far the switch cylinder has extended Dimension E1 Start the machine up Allow the switch cylinder 2 to extend to its end position Shut the machine down Measure how far the switch cylinder has...

Page 297: ...s setting must be checked after a running in period of approxima tely 100 operating hours Mount all protective covers and other safety equipment and make sure they are fully functional After completin...

Page 298: ...Therefore always read the chapter Safety regulations and the description Other risks during maintenance work at the be ginning of the Maintenance chapter Refer also to the maintenance charts Discharge...

Page 299: ...the line coupling Disconnect the delivery line Remove all necessary lubrication lines and seal them with plugs Replace the S transfer tube if the wall thickness has fallen below the minimum Measure th...

Page 300: ...nd S transfer tube bearing Pushing S transfer tube away Push the S transfer tube away from the wear stay Slide the S transfer tube forwards until the transfer tube outlet is free Lift out the S transf...

Page 301: ...equipment Do not damage the trans fer tube when cutting open the wear sleeve 1 Item Designation 1 Wear sleeve You must carefully cut the wear sleeve with a metal cutting ma chine in two opposite place...

Page 302: ...S transfer tube bearing Maintenance chart Discharge connection and S transfer tube bearing Check the gap and correct it if necessary Maintenance chart Adjusting S transfer tube Check the switching ove...

Page 303: ...ried out Remove the lifting gear from the S transfer tube Install all necessary lubrication lines Lubricate all bearings well until grease visibly begins to escape Refit all the removed safety equipm...

Page 304: ...risks during maintenance work at the be ginning of the Maintenance chapter No further maintenance charts required The following special tool is required Torque wrench Caution Maintenance work must on...

Page 305: ...signation 1 Trailer coupling ring 2 Ball hitch 3 Cable ties 4 Rubber gaiter 5 Fastening bolt Remove the cable ties 3 Pull back the rubber gaiter 4 over the fastening bolts 5 Unscrew the nuts from the...

Page 306: ...r Viewed from the direction of travel always insert the fastening bolts from the left hand side Screw on the new self locking nuts and tighten with the tighte ning torque specified in the table The ty...

Page 307: ...C 77 A 2 M 12 8 8 86 Nm B 2 M 12 8 8 86 Nm Trailer ball hitch tightening torque Type Model Number of bolts Bolt dimensions Tightening torque AK 160 A and B 2 M 12 8 8 86 Nm AK 300 2 M 12 8 8 86 Nm AK...

Page 308: ...tenance work at the be ginning of the Maintenance chapter No further maintenance charts required The following special tool is required Wall thickness measuring device Notes Delivery lines are subject...

Page 309: ...ine thoroughly Refer also to chapter Operation section Cleaning Danger Shut down the machine before starting work and secure it against unauthorised or accidental starting Ensure that all pressures in...

Page 310: ...s supplied with the measuring device when carrying out measurements Mea sure the wall thickness of the S transfer tube particularly at the stress points 12501601 Area of increased load The minimum wal...

Page 311: ...ating pressure can rise to the ma ximum pressure in the event of a blockage and in this case the wall thickness may no longer be adequate Measure the wall thickness of the delivery line with the wall...

Page 312: ...ue pumping with a delivery pressure lower than that shown in the graph We should however draw your attention to the fact that the delivery line is subject to varying loads as a result of the dynamic l...

Page 313: ...function of delivery 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...

Page 314: ...r Notes Maintenance inspection and servicing work poses a particular risk of accident Therefore always read the chapter Safety regulations and the description Other risks during maintenance work at th...

Page 315: ...rotection measures Set the lever on the switchover valve to the Pumping position The high pressure cleaner is switched off Shut off the water supply Disconnect the water supply line Open the cleaning...

Page 316: ...3 8 120 WK52_006_1203GB Caution The high pressure cleaner must not be allowed to run dry Ensure that the lever of the switchover valve is in the Delivery posi tion Check the switchover valve The leve...

Page 317: ...ing work poses a particular risk of accident Therefore always read the chapter Safety regulations and the description Other risks during maintenance work at the be ginning of the Maintenance chapter R...

Page 318: ...otection measures Set the lever on the switchover valve to the Pumping position The flushing water pump switches off Shut off the water supply Disconnect the water supply line Disconnect the pressuris...

Page 319: ...refore always read the chapter Safety regulations and the description Other risks during maintenance work at the be ginning of the Maintenance chapter Refer also to the maintenance charts High pressur...

Page 320: ...enter the high pressure cleaner Top up the fluid level of the high pressure cleaner to the middle of the inspection glass Caution The high pressure cleaner requires a year round high pressure multi gr...

Page 321: ...ntervals in the maintenance summary at the start of this chapter Notes Maintenance inspection and servicing work poses a particular risk of accident Therefore always read the chapter Safety regulation...

Page 322: ...indicator lamp signals an empty message depending on mo del by flashing with brief intervals Fill with clean lubricant at regular intervals Use a multipurpose grease of consistence class NLGI 2 or a...

Page 323: ...er of crushing when filling the grease distributor through the lid Never reach into the open grease distributor while the centralised lubrication pump is operating Unscrew the lid 1 from the grease di...

Page 324: ...otective caps if necessary Assemble the cartridge 4 if necessary Clean the filling nipple and the cartridge filler connection tho roughly with a clean cloth Push in the plunger rod 5 on the cartridge...

Page 325: ...in the control cabinet de pending on the model of the centralised lubrication system At the end of maintenance work the following tasks must be carried out Start the engine Refer also to chapter Start...

Page 326: ......

Page 327: ...the machine is to be shut down temporarily take the following mea sures Stop the supply of material Empty the material hopper Switch the pump off at toggle switch Pump ON 0 Reverse pumping ON Switch...

Page 328: ...nto hot machine components when refuelling There is a risk of the fuel igniting Avoid naked flames at the machine and lock the fuel tank after re fuelling risk of fire Do not spill fuel When filling w...

Page 329: ...me you must remove the battery and charge it regularly Protect the machine with a suitable agent Notes Preservation and greasing the machine prevents corrosion and pre mature ageing It is necessary if...

Page 330: ...Final disposal of the machine is carried out by a qualified specialist company Danger During final decommissioning of the machine escaping lubricants solvents preserving agents etc represent hazards...

Page 331: ...rts Pump units Gaskets Plastic rubber PVC Hoses Cables Tin PCBs Polyester PCBs The following components and working materials must be separated prior to disposal Designation Applies to Electrical supp...

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Page 333: ..._0028_1412GB 10 Appendix This chapter includes the documents listed below Lubricant recommendation Sample EC Declaration of Conformity You may find additional documents in the appendix depending on th...

Page 334: ...fluids or lubricants with additives such as mo lybdenum These additives may corrode the bearings Danger Never mix hydraulic fluids with different characteristics i e do not mix biologically degradabl...

Page 335: ...xing fluids When hydraulic fluid is changed approx 10 15 of the old hy draulic fluid remains in the system cylinder pump lines etc When a different oil grade is used observe conversion regulations as...

Page 336: ...5 W 40 Characteristics mineral Requirements standard API CF CF 4 Viscosity DIN DIN 51 511 mm2 s ISO VG 112 Application range 15 C to 40 C Notes The drive motor has already been filled by the respectiv...

Page 337: ...51502 K2K 20 Requirements standard DIN 51 825 Characteristics mineral lithium soap Viscosity grade NLGI Class NLGI Class 2 DIN 51 818 Type Engine oil Model SAE 15 W 40 Characteristics mineral Requirem...

Page 338: ...Appendix 10 6 11_0025_1407GB The original EC declaration of conformity is included in the machine s scope of supply Store this in a safe place 10 2 Template for EC de claration of confor mity...

Page 339: ...e main key words with the number of the page on which they are to be found as a header in the left hand mar gin This Index of key words is listed alphabetically by the main con cepts These are subdivi...

Page 340: ...Pump assembly and post washing operations 6 31 Residual concrete 6 16 Suction cleaning 6 24 T delivery pipe with cleaning port 6 20 Wash out adapter 6 19 Cleaning preparations 6 17 Compressed air clea...

Page 341: ...er 5 17 8 35 Reverse coarse filter 8 39 Reverse fine filter 5 17 8 36 Hydraulic fluid Troubleshooting 7 6 7 12 Hydraulic hose lines 5 5 Hydraulic hoses 8 42 Flared screwed joints 8 44 Hydraulic pump 3...

Page 342: ...fica tions 2 10 Qualified personnel 2 10 Subject expert 2 10 Training 2 10 Place of work 2 26 Pressure calibrator 3 20 Protective boots 2 15 Protective equipment 3 9 Ear defenders 2 13 Face mask and r...

Page 343: ...chine components 2 11 Spare parts 2 29 Spare parts sheets 2 29 SRP 2 28 Starting up Function checks 5 16 Operating materials 5 3 Starting the drive motor 5 10 Switching on pump 5 14 Storing the machin...

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Page 345: ...Uruguay USA Venezuela VAE Vietnam Zypern Weitere Werksvertretungen mit Kundendienst in Putzmeister M rtelmaschinen GmbH Putzmeister Limited Putzmeister France Max Eyth Stra e 10 72631 Aichtal Postfach...

Page 346: ...Putzmeister M rtelmaschinen GmbH Max Eyth Str 10 72631 Aichtal Tel 49 7127 599 0 Fax 49 7127 599 743 Service Hotline 49 7127 599 699 Mail mm pmw de Web www pmmotar de...

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Putzmeister P 718 SD, Translation Of The Original Operating Instruction

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