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Waitzinger THP 94/42 R 4 XXT, User Manual

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Waitzinger THP 94/42 R 4 XXT User Manual Download Page 117

M

AINTENANCE

 & I

NSPECTION

C

HAPTER

 9

9-7

THP 94/42 R 4 XXT
THP 125/42 R 4 XXT
THP 140 H/42 R 4 XXT

GB-07.2005

Thread Ø

M8

23

32

M10

46

64

M12

80

110

M14

125

180

M16

195

275

M18

270

390

M20

385

540

M22

510

720

M24

660

930

M27

980

1.400

Tightening torque M

D  

[Nm]

8.8

Tightening torque M

D  

[Nm]

10.9

Fig. 9.1   Tightening torque for screw connections

9.3

Tightening torques for screw connections

The following values apply to tightening torques for machine screws to DIN 912, 931 and 934 based on a friction
factor of 

µ

 = 1.25 (lightly oiled).

Summary of Contents for THP 94/42 R 4 XXT

Page 1: ...Waitzinger Baumaschinen GmbH User manual WAITZINGER CONCRETE PUMP THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT...

Page 2: ...copyright to Waitzinger Baumaschinen GmbH This document contains instructions and technical drawings and may therefore not be copied and released to third parties in whole or in part Errors and omiss...

Page 3: ...ety instructions for the working area 2 11 2 9 1 Distributor boom 2 12 2 9 2 Conveying pipes 2 12 2 9 2 1 Locking the conveying pipe connections 2 13 2 9 2 2 Opening the conveying pipe connections 2 1...

Page 4: ...rete pump 3 4 4 Description 4 1 4 1 Proper use 4 1 4 2 Structure and function of the concrete pump 4 2 4 2 1 Structure of the concrete pump 4 2 4 2 2 Function of the concrete pump 4 4 4 2 2 1 Distribu...

Page 5: ...before starting up 7 4 7 2 1 Changeover to transfer shift gearbox 7 4 7 2 2 Emergency Stop 7 5 7 2 3 Selecting the operating mode 7 6 7 3 Operating the outriggers 7 6 7 3 1 Stability checking 7 7 7 3...

Page 6: ...for pumping 7 25 7 6 3 Instructions for pumping depending on the material to be pumped 7 26 7 6 4 Instructions for pumping depending on the machine 7 27 7 6 4 1 Measures to reduce the oil temperature...

Page 7: ...5 3 Sliding surfaces 9 14 9 5 4 Overview of grease points 9 14 9 5 5 Reference tables for hydraulic oils greases and gear oils 9 16 9 6 Changing filters 9 19 9 6 1 General 9 19 9 6 2 High pressure fi...

Page 8: ...he agitator blades 9 33 9 9 5 Changing the agitator seals 9 34 9 9 6 Changing the agitator wear sleeves 9 34 9 10 Changing the conveying pipework 9 35 9 11 Crack checking on the steelwork 9 35 9 12 Ch...

Page 9: ...ll repair work should be performed only by authorised skilled staff If maintenance work is neglected or improperly performed we may no longer be liable to perform our warranty obligations under our co...

Page 10: ......

Page 11: ...ondition and in a proper manner see section 4 2 Proper use Any use other than this or beyond this is deemed to be improper use If the machine is used inappropriately or improperly risks to life and li...

Page 12: ...ual or the operating and maintenance handbook for the overall system accidents leading to personal injuries and or damage to property occur this circumstance releases WAITZINGER from any liability for...

Page 13: ...serious effects on health through to life threatening injuries CAUTION This symbol indicates a situation that may possibly be dangerous Disregard of this information can lead to minor injuries or dama...

Page 14: ...d concrete pump suitable safety equipment should be worn particularly when handling mortar additives The symbols for the necessary safety equipment are shown in the graphics panel alongside The symbol...

Page 15: ...lification of truck mounted concrete pump operators VDMA Safety Handbook VBG 1 General instructions VBG 4 Electrical systems and equipment VBG 5 Power operated equipment VBG 8 Winches hoists and drawg...

Page 16: ...consumable materials to TA waste code 524 02 should be to EC directive 91 689 EWG Consumables such as lubricants cleaning materials during maintenance repair and oil change should be collected in suit...

Page 17: ...pipes when they are under pressure due to a blockage Injuries due to reaching into the agitator hopper or falling into it Injuries due to slipping from or on the oily and slippery walkways on the mach...

Page 18: ...cation if necessary have someone guide the driver to the location Keep a safe distance from obstacles such as site cranes buildings and equipment Check there is sufficient room to extend the outrigger...

Page 19: ...ficient distance from embankments pits excavations and other holes so that the pressure of the outriggers on the ground does not cause it to break into the hole 2 7 3 2 Safety distances to the edges o...

Page 20: ...nd quality is insufficient to accept this the bearing area should be enlarged with two crossed layers of support plates See DIN 1054 for recommended values Fig 2 5 Ground Premissible ground pressure N...

Page 21: ...w otherwise an assistant is necessary When leaving the machine secure it against unauthorised use and self acting movement Barrier off the working area to other traffic in accordance with instructions...

Page 22: ...ual Add extensions to the conveying pipe to the distributor boom only if they do not place any additional load on the boom When the wind reaches the critical speed retract the distributor boom and sec...

Page 23: ...nd rotate the elbows 180 Check the minimum wall thicknesses and operating pressure WARNING If you use compressed air for cleaning the conveying pipes this is at your own risk WAITZINGER accepts no lia...

Page 24: ...e at risk or overload the steel structure The freely suspended discharge hose must not be extended with additional couplings discharge pieces or other hazardous discharge arrangements The discharge ho...

Page 25: ...ts 2 9 3 3 Use the guide rod to hold the discharge hose Do not hold the discharge hose by hand if necessary to guide it use the guide rod as shown here 2 9 3 4 Securing the discharge hose with the cat...

Page 26: ...e machine operator must take the following safety precautions and perform the following tests a Use only pipework supplied by the concrete pump manufacturer At concrete pressures between 85 bar and 13...

Page 27: ...ay only be performed by persons appointed by the manufacturer Special care must be taken in respect of boom mountings and outriggers used as hydraulic or diesel tanks When replacing electrical pneumat...

Page 28: ...If the minimum safety distance from overhead electric cables shown in the table cannot be maintained the machine operator must ensure that they are switched off for the duration of the work or they a...

Page 29: ...t potentials step voltage so that the current flows through the body in proportion to the potential difference If a high tension contact occurs keep calm stand still step voltage and don t touch anyth...

Page 30: ...itute first aid measures If despite all precautions a high tension cable contact occurs keep calm stand still step voltage and don t touch anything Tell those around to keep their distance step voltag...

Page 31: ...81 4 dB A 2 16 Environmental protection Use should be found around the building site for surplus concrete or it should be disposed of as building waste according to the statutory requirements Consuma...

Page 32: ...eration and maintenance of the machine They must have proved their capability to the user They must be expected to fulfil their duties reliably Personnel must not wear any loose clothing or jewellery...

Page 33: ...WAI106367 Crush hazard 17 WAI105976 Distributor boom range 18 WAI105942 Spring plug 19 WAI106769 Distributor boom serial plate 20 WAI105935 Coupling pipe wall thickness 21 WAI105936 Keep hands out of...

Page 34: ...RUCTIONS AND INFORMATION CHAPTER 2 THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 2 24 Fig 2 17 Item 1 WAI106179 Serial plate Fig 2 18 Item 2 WAI106032 Matching pipe lenghts Conv...

Page 35: ...SAFETY INSTRUCTIONS AND INFORMATION CHAPTER 2 THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 2 25 Fig 2 19 Item 3 WAI105933 WAI105932 General instructions GB D...

Page 36: ...CTIONS AND INFORMATION CHAPTER 2 THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 2 26 Fig 2 20 Item 4 WAI105944 Safety equipment Fig 2 21 Item 5 WAI105934 High tension overhead el...

Page 37: ...Y INSTRUCTIONS AND INFORMATION CHAPTER 2 THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 2 27 Fig 2 22 Item 6 WAI105974 Keep away Abb 2 23 Item 7 WAI105938 Remotely controlled mac...

Page 38: ...RUCTIONS AND INFORMATION CHAPTER 2 THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 2 28 Fig 2 24 Item 8 WAI105937 Boom is not a crane Fig 2 25 Item 9 WAI105975 Total weight of dis...

Page 39: ...RUCTIONS AND INFORMATION CHAPTER 2 THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 2 29 Fig 2 26 Item 10 WAI105940 Slewing range of boom Fig 2 27 Item 11 WAI105941 Extending the s...

Page 40: ...CHAPTER 2 THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 2 30 Fig 2 28 Item 12 WAI105939 Do not reach into the hopper Fig 2 29 Item 13 WAI106369 Grease point Fig 2 30 Item 14 WA...

Page 41: ...Y INSTRUCTIONS AND INFORMATION CHAPTER 2 THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 2 31 MAX 3 Fig 2 31 Item 15 WAI106366 Max inclination 3 Fig 2 32 Item 16 WAI106367 Crush h...

Page 42: ...T THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 2 32 5 5 0 15 10 15 25 20 10 25 20 35 30 45 40 5 0 5 45 40 50 35 30 25 20 15 10 20 15 10 30 25 35 29 m 42 m 38 m 0 370 10 200 9 250 9 250 9 250 235...

Page 43: ...CHAPTER 2 THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 2 33 Fig 2 34 Item 18 WAI105942 Spring plug Fig 2 36 Item 20 WAI105935 Coupling pipe wall thickness Fig 2 35 Item 19 WAI1...

Page 44: ...RUCTIONS AND INFORMATION CHAPTER 2 THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 2 34 Fig 2 37 Item 21 WAI105936 Keep hands out of water box Fig 2 38 Item 22 WAI105943 Disengage...

Page 45: ...SAFETY INSTRUCTIONS AND INFORMATION CHAPTER 2 THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 2 35 Fig 2 39 Item 23 WAI106477 WAI106478 Safety instructions GB D...

Page 46: ...4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 2 36 Fig 2 40 Item 24 WAI106348 Operating panel right hand outrigger Fig 2 41 Item 25 WAI106349 Operating panel left hand outrigger WAI106519 F...

Page 47: ...PTER 2 THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 2 37 Fig 2 43 Item 27 WAI106030 Operating panel agitator Fig 2 44 Item 28 WAI106031 Operating panel water pump Fig 2 45 Item...

Page 48: ......

Page 49: ...concrete pump Vehicle dimensions approx 13 070 mm x 2 500 mm x 3 980 mm Length x Width x Height Weight approx 31 900 kg in full working order 3 2 Truck Information regarding the truck can be found in...

Page 50: ...Max slope of ground degrees 3 Front outrigger pressure kN 220 Rear outrigger pressure kN 220 Max concrete pressure bar 85 Max weight of pipework kg m 12 Max weight of elbow kg 13 Max density of concr...

Page 51: ...XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 3 3 5 5 0 15 10 15 25 20 10 25 20 35 30 45 40 5 0 5 45 40 50 35 30 25 20 15 10 20 15 10 30 25 35 29 m 42 m 0 370 10 200 9 250 9 250 9 250 235 180...

Page 52: ...15 19 Conveying cylinder Dinner x stroke mm 200 x 2 000 230 x 2 000 230 x 2 000 Stroke volume double stroke litre 125 166 166 Hydraulic drive cylinder Dpiston Drod x stroke mm 125 80 x 2 000 125 80 x...

Page 53: ...oper use is deemed to be improper use or misuse WAITZINGER accepts no liability for damage that arises under such circumstances The truck mounted concrete pump as delivered is in accordance with curre...

Page 54: ...following major subassemblies 1 Catch hook 2 Rear outrigger catches in transport position 3 Water tank filling and drain cock 4 Outrigger control block left 5 Telescope limit of travel catch front 6 C...

Page 55: ...Boom element A 5 Boom element B 6 Boom element C 7 Boom element D 8 Discharge hose 9 Front outrigger cylinder 10 Front telescopic section 11 Transfer shift gearbox 12 Rear outrigge 13 Rear outrigger...

Page 56: ...telescopic front outriggers are hydraulically swung out and extended The hydraulic support cylinders ensure the necessary stability of the truck mounted concrete pump The rear outriggers contain the w...

Page 57: ...p to continue to be run at a reduced speed should the control system or the sensors fail The stroke rate can be varied between minimum and maximum The drive cylinders 1 are fitted with an automatic le...

Page 58: ...conveying pipe Concrete is sucked into the right hand conveying cylinder through the free opening in the hopper As soon as sensor S12 trips valves Y4b and Y5b are started The drive cylinders remain s...

Page 59: ...ater tank drain cock 4 Outrigger control block right 5 Boom control block 6 Control elements on the control cabinet 7 Control panel desk 8 Control panel agitator water pump 9 Surplus concrete discharg...

Page 60: ...ontrols on 4 Indicator lamp Hydraulic oil temperature 5 Control panel lighting 6 Rocker switch Horn Reset Lubrication 7 Rocker switch Light 8 Rocker switch Vibrator Auto Manual 9 Rocker switch Engine...

Page 61: ...07 2005 5 3 5 3 Control panel agitator water pump 1 Manometer Agitator Water pump 2 Display instrument Concrete pump 3 Manometer protection valve 4 Control lever Water pump Additional Equipm optional...

Page 62: ...ighting for control panel 3 Emergency Stop button 4 Control lever Outrigger Boom 5 Control lever Deploy and retract boom element D 6 Control lever Deploy and retract boom element C 7 Control lever Dep...

Page 63: ...3 Outrigger safety button 4 Control lever Extending retracting the rear outrigger cylinder 5 Control lever Slewing the rear outrigger out in 6 Control lever Slewing the front outrigger out in 7 Contr...

Page 64: ...op button 3 Circular level 4 Control lever Extending retracting the front outrigger cylinder 5 Control lever Extending retracting the front outrigger telescope 6 Control lever Slewing the front outrig...

Page 65: ...125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 5 7 5 7 Control cabinet 1 Display instrument Operating hours 2 Rotary switch Back up function A 0 B 3 Indicator lamp Fault 4 Indicator lamp Lubrication...

Page 66: ...earbox on 2 Key switch Transfer shift gearbox on off 5 9 Surplus concrete discharge opening 1 Lever Surplus concrete discharge opening 2 Adjusting screws 5 10 Water tank shut off valve 1 Ball valve Wa...

Page 67: ...ploy and retract boom elements C and D 2 Joystick Deploy and retract boom element B 3 Joystick Deploy retract and slew boom element A 4 Push button Start engine 5 Push button Stop engine 6 Push button...

Page 68: ...ed concrete pump at the following places Control panel desk Outrigger control block right Boom control block Radio remote control Outrigger control block left Cable remote control 5 14 Control element...

Page 69: ...ts on the truck mounted concrete pump to ensure they are in good condition check the outrigger catches to ensure they are properly engaged check that all components are secured against free movement c...

Page 70: ...g CAUTION Not all the identified lifting points are suitable for lifting the complete machine Always check before lifting The attachment points for lifting the truck mounted concrete pump are specific...

Page 71: ...r Only when the operating safety has been assured in this way may the truck mounted concrete pump be started up NOTE During start up and operation comply with the safety instructions set out in Chapte...

Page 72: ...or alignment and degree of wear wall thickness measurement b 2 During operation Never allow the machine to operate unattended Stop the machine immediately if any fault occurs that might create a safet...

Page 73: ...g capability Fully deployed outriggers right Space requirement at the front 8 5 m 0 6 m 9 1 m Space requirement at the rear 8 0 m 0 6 m 8 6 m Slewing range 0 360 Narrow outriggers one side Space requi...

Page 74: ...st be in the ON position vehicle engine can run but need not be running the pneumatic pressure must be more than 5 bar and the clutch fully disengaged The indicator lamp 1 lights up when the gearbox i...

Page 75: ...op buttons are located as follows Control panel desk Item 1 Fig 5 2 Boom control block Item 3 Fig 5 4 Left hand outrigger controls Item 2 Fig 5 5 Right hand outrigger controls Item 2 Fig 5 6 Radio rem...

Page 76: ...functions on the control panel desk Pump Suck 11 and Stroke rate 13 are disabled if the remote control is activated The key switch 14 allows switching between Control Desk and Remote control If the ca...

Page 77: ...unimpeded view of the entire hazard area When activating the functions with the respective operating lever for safety reasons the other hand should always be keeping the safety button Item 3 Fig 5 5 I...

Page 78: ...unctions on the outrigger 1 Circular level 2 Emergency Stop button 3 Outrigger safety button 4 Extending retracting the rear outrigger cylinder 5 Slewing the rear outrigger cylinder out in 6 Slewing t...

Page 79: ...t the arrows match see detail right indicating the that the outrigger is fully extended Extend the front outrigger cylinder so far that the front wheels are lifted clear of the ground The rear wheels...

Page 80: ...4 1 Distributor boom operation using the master control block NOTE Distributor boom operation using the master control block should only be used as back up Whenever possible control the boom using the...

Page 81: ...ver boom A Item 8 Fig 7 11 and deploy the boom package until the catch hook releases Press the boom rotation control lever Item 9 Fig 7 11 to rotate the boom package into the working position Catch ho...

Page 82: ...HP 140 H 42 R 4 XXT GB 07 2005 7 12 Press control lever B Item 7 Fig 7 11 and deploy boom element B at 120 to boom element A Press control lever C Item 6 Fig 7 11 and deploy boom element C at 90 to bo...

Page 83: ...l levers Items 5 to 9 Fig 7 11 on the boom control block to move the distributor boom into the desired working position WARNING When using manual control at the boom control block all safety circuits...

Page 84: ...until the catch hook releases and the boom element B can be deployed see Fig 7 12 Press the master switch Deploy boom element A Slew boom 3 to move the distributor boom into the position where the di...

Page 85: ...owing Press the master switch Deploy boom element A Slew boom Item 3 Fig 7 18 and deploy boom element A until the catch hook releases and the boom element B can be deployed see Fig 7 12 Press the mast...

Page 86: ...he operating mode selection switch Item 14 Fig 7 21 must be set to Desk The rocker switch Item 11 Fig 7 21 selects Pump or Suck For confirmation one of the two indicator lamps Item 10 or 12 Fig 7 21 w...

Page 87: ...d NOTE Opening the safety grill or pressing an Emergency Stop button whilst the Pump Suck switch is activated will deactivate the Pump Suck function which must then be restarted by switching the rocke...

Page 88: ...Fig 7 22 NOTE If the pressure at the pressure switch is set too low the stroke will be short and the S valve may not swing over fully If the pressure at the pressure switch is set too high the pump c...

Page 89: ...crewdriver 4 mm or similar tool Then press Y3 manually and move the drive cylinder to the desired position Simultaneously releasing Y3 and Y4 will bring the cylinder to a halt Moving the oscillation c...

Page 90: ...on even when the Emergency Stop button has been pressed The agitator should always be set to move the concrete inwards to the centre push the control lever to the right Setting the agitator to move t...

Page 91: ...ater pump or compressor available as an option are controlled by the same control lever Item 4 Fig 7 24 7 5 7 Vibrator The control lever Vibrator Item 8 Fig 7 24 switches the vibrator on Two operating...

Page 92: ...optional and working area floodlights The lighting around the outrigger feet is permanently switched on It needs only be plugged into the appropriate socket on the outrigger foot 7 5 10 Concrete pump...

Page 93: ...he display instrument Item 2 Fig 7 27 shows the degree of clogging of the in line filter If the needle indicates 3 bar the filter cartridge must be changed 7 5 10 3 Manometer for transfer shift gearbo...

Page 94: ...advance Pump slowly until a full stream of concrete emerges from the discharge hose If the conveying pipework is short and clean immediately before starting pumping with the agitator running fill the...

Page 95: ...aw any air in since compressed air can emerge violently at the discharge hose causing concrete to spray out Therefore keep the hopper filled at least up to the level of the agitator shaft When pumping...

Page 96: ...to stand under pressure If the concrete is very fluid with a high proportion of large gravel and tends to bleed from the conveying pipework always pump out into the hopper during pauses in pumping Du...

Page 97: ...of approx 1 000 rpm This is particularly important for turbo diesel engines Set the engine speed to more than the minimum speed 500 700 rpm Damage due to operator error is not covered by the WAITZINGE...

Page 98: ...tout is located in the hydraulic oil tank 7 7 Cleaning the conveying pipework 7 7 1 General Do not use any aggressive cleaning additives for cleaning the conveying pipework Put the remote control pend...

Page 99: ...e drained at normal temperatures during long pauses in pumping overnight and at weekends 7 7 3 Cleaning with pressurised water Cleaning the machine with pressurised water is a method well proven in pr...

Page 100: ...e pump If the protective grill has a safety cut out agitator and S valve come to a halt as soon as the protective grill is opened When cleaning briefly shut the protective grill let the pump run throu...

Page 101: ...hapter 2 Safety instructions 7 8 Water tank 7 8 1 Filling up topping up with water by removing the cover Close all ball valves Unscrew the cover 1 on the rear outrigger Fill with water of a suitable q...

Page 102: ...7 39 Start filling with water watch the water sight hose Item 2 Fig 7 37 Keep filling with water until water emerges from the filler opening 7 8 4 Operation in winter The machine must be standing lev...

Page 103: ...nition position Clutch was not disengaged Disengage the clutch and engage the required gear Pressure in vehicle compressed Allow the engine to run until air system too low It has built up sufficient p...

Page 104: ...ng does not Selector switch in position Move selector switch to position start no pressure available Desk Remote control operate horn Grill open Close grill Check limit switch Pump ON was selected whe...

Page 105: ...the blockage see section 7 6 1 1 Defective sensor on drive cylinder Set back up function to position B Replace the defective sensor at the earliest opportunity Spool valve defective Check valve and so...

Page 106: ...5 2 to position Desk or set remote control Item 8 Fig 5 12 to position Outriggers Safety switch on the outrigger Set safety switch Item 3 Fig 5 5 has not been pressed or Item 1 Fig 5 6 Engine not runn...

Page 107: ...5 12 to position Boom Engine not running Start the engine Vehicle gearbox in neutral Select a gear see section 7 2 1 Emergency Stop button has Establish why the Emergency Stop been pressed button was...

Page 108: ...lean the pressure relief valve Seek advice WAITZINGER customer service on this point Hydraulic pump defective Have pump replaced by WAITZINGER customer service Individual boom movements Solenoids in t...

Page 109: ...Ball bearing slewing rim Lubricate the ball bearing slewing insufficiently lubricated rim Slewing motor worn Have motor replaced by WAITZINGER customer service The boom slews although Slew Brake in s...

Page 110: ...water pump and clean it See separate user manual from the manufacturer Axial play in the pump shaft Undo the coupling and adjust incorrect to the mid value Lubrication system does not Fuse blown Repl...

Page 111: ...rt of the vehicle can be found in the separate vehicle manufacturer s user manual 9 2 Safety instructions for maintenance and inspection Maintenance and inspection of the truck mounted concrete pump m...

Page 112: ...reakage corrosion and secure mounting Regularly check all pipes hoses and screwed connections for leaktightness and for externally evident damage Fluids which emerge at high pressure can be hazardous...

Page 113: ...400 C they decompose e g if equipment catches fire The remains of such seals are then extremely aggressive and generally cannot be removed from the skin 9 2 3 Oils and greases WARNING Allergic reacti...

Page 114: ...ntilation and never smoke When spraying paint always wear a close fitting face mask Never allow petrol or paraffin to come into contact with rubber components Contamination of rubber components with t...

Page 115: ...protective clothing and protective gloves Handle batteries with care If any battery acid splashes on to the skin wash it off immediately with clean water If any battery acid splashes on to the eye wa...

Page 116: ...before working on the electrical system Electric arcs can be life threatening and cause fires Do not place anything metallic on the battery Sulphuric acid is corrosive When working on the battery alwa...

Page 117: ...195 275 M18 270 390 M20 385 540 M22 510 720 M24 660 930 M27 980 1 400 Tightening torque MD Nm 8 8 Tightening torque MD Nm 10 9 Fig 9 1 Tightening torque for screw connections 9 3 Tightening torques fo...

Page 118: ...ery 1 000 operating hours or annually After the first 50 operating hours Check all components for wear deformation corrosion and secure mounting Check oil fuel grease and water levels top up as necess...

Page 119: ...security of all snap couplings Check the oil level in the slewing gearbox Check the adjustment of the S valve and adjust it as necessary Perform all necessary maintenance work on the truck in accorda...

Page 120: ...S valve verify 8 mm wall thickness Check the oil level in the transfer shift gearbox Perform a wear check on the conveying cylinders Clean the diesel pre filter on the vehicle Check that the conveyin...

Page 121: ...nge the breather filter on the hydraulic oil tank Check all safety equipment that is fitted for good condition Change the oil in the slewing gearbox see section 9 7 1 Check play within the ball bearin...

Page 122: ...tuate the lubrication system for approx 2 sec CAUTION Check whether the rotor vane on the lubrication pump rotates and sufficient grease is fed in If grease emerges from the safety valve no grease poi...

Page 123: ...off 6 Lubricating manually CAUTION Before starting work check that grease is issuing at all grease points see point 2 If the central lubrication system is defective all grease points can be lubricate...

Page 124: ...40 H 42 R 4 XXT GB 07 2005 9 5 2 Manual lubrication An acid free multi purpose grease should be used for manual lubrication see Figure 9 5 9 5 3 Sliding surfaces Use graphite grease for sliding surfac...

Page 125: ...Schmiernippel 2 Schmiernippel 2 Schmiernippel gegen berliegend 2 2 Schmiernippel gegen berliegend 2 Schmiernippel auf der Innenseite 2 Schmiernippel auf der Innenseite gegen berliegend 2 2 Schmiernip...

Page 126: ...TION Hydraulic oils with different characteristics biologically degradable mineral based hydraulic oils must on no account be mixed Engine oil data can be found in the separate user manual issued by t...

Page 127: ...togel S2 Kl berbio M32 82 Ca Ca Li Ca Ca Ca Li Ca Li Ca Ca Li Li inorg thinner Li Ca Li Li Li Ca Ca Li Li Li Ca Ca 20 C 10 C Top 8000 W Ca 20 C C1 Abschmierfett Ca 20 C High pressure grease Ca 25 C 20...

Page 128: ...DTE 11 Shell Tellus l T 15 15 10 15 Degol GS 460 Energol SG XP 460 UK Ecubsynth l PG 460 Alphasyn T 460 Polydea CLP 460 Kl bersynth GH 6 460 Mobil Glygoyle 80 Shell Tivela Oil SD 460 100 25 Degol GS 2...

Page 129: ...s involves some loss of hydraulic oil Therefore be sure always to have a container or oil barrel to hand Filters should be changed in a short a time as possible so that there is the least opportunity...

Page 130: ...If the clogging indicator Item 1 Fig 9 8 is in the red zone when the oil is at operating temperature the filter element must be changed 1 Have a suitable container ready for the oil filter element and...

Page 131: ...ne oil circuit oil circuit A Use only gear oil as shown in the gear oil reference table Fig 9 6 Use oil grades alternative grades as shown in the gear oil reference table Fig 9 6 Oil capacity 10 litre...

Page 132: ...the oil after this repeat point 1 3 Reinsert the drain plug 4 Use a funnel to fill the gearbox slowly with oil through the breather screw opening 3 until the oil comes out of the oil level screw hole...

Page 133: ...le 7 Pour hydraulic oil into the hydraulic tank through the return flow filter element or pump it in using a pump with a fine filter CAUTION Never pour hydraulic oil into the tank directly from the ba...

Page 134: ...NGER Only knock the conveying pipes apart and open them when they have been depressurised Always pump backwards 1 2 piston strokes Check the wear condition of the conveying pipework by knocking it or...

Page 135: ...70 60 50 40 30 20 10 0 Concrete pressure bar Minimum wall thickness mm 0 1 2 3 3 6 4 5 6 7 8 X Y Fig 9 16 Minimum wall thickness diagram 9 8 2 Minimum wall thicknesses and conveying pipework operating...

Page 136: ...m then back off by 30 3 Refit the locking plate 4 Perform a trial run of the concrete pump 9 8 4 Checking the chain tension on the outrigger feet When the chain tension is correctly set the chin shoul...

Page 137: ...t slightly until a tooth is engaged without play 3 Insert a feeler gauge to measure the engagement clearance as shown in the adjoining diagram 4 If the backlash is excessive the gearbox and the ball b...

Page 138: ...Ds One LED Green Switch activated Two LEDs Green Power on Yellow Switch activated 2 On the 4 fold distributor there are Two green LEDs Power for the sensors Each with a yellow LED Switch activated Dri...

Page 139: ...2 and 3 to relieve the load on the S valve by 15 mm 2 Exchange the free wear plate 4 by removing the first 2 screws 6 and tighten the screws 3 Swing the S valve over to the other side 4 Remove the sec...

Page 140: ...key Never reach your hands into the wash out tank when the engine is running Always actuate the hydraulic cylinder by actually actuating the valves see section 7 5 4 3 at a low engine speed and reduc...

Page 141: ...Fig 9 29 Changing the conveying piston 4 1 4 Fig 9 30 Changing the conveying piston 5 5 Carefully move the drive cylinder out until it touches the flange Fit a snap coupling 4 6 Move the drive cylinde...

Page 142: ...turning the conveying cylinder 1 Remove the conveying cylinder as described in section 9 9 2 2 Move both drive cylinders to the limit of their travel Disconnect the oscillation pipe from a retracted d...

Page 143: ...s in the reverse sequence to removal 8 Fit the conveying pistons and oscillation pipe as described in section 9 9 2 9 Manually activate valves Y3 and Y4 or the rocker switch Item 11 Fig 5 2 to slowly...

Page 144: ...th grease 6 Reassemble the motors 4 and shafts 3 together with the agitator blades in the reverse sequence to removal see Fig 9 24 9 9 6 Changing the agitator wear sleeves 1 Remove the motors Item 4 F...

Page 145: ...bly CAUTION A distance of 3 mm must be maintained between the flanges Arrange the Matching pipe lengths Conveying pipes as shown in the safety notice in Figure 2 16 9 11 Crack checking on the steelwor...

Page 146: ...dent damage The period of time can be calculated from the identification mark on the connection fitting date of manufacture of the hose 9 13 Cleaning the machine If the truck mounted concrete pump is...

Page 147: ...ns and check the machine for chafing points Check all components for any sort of damage If faults are found rectify them immediately If there is a risk of frost completely drain the conveyor pipework...

Page 148: ......

Page 149: ...rovision will render the warranty void and relieve the manufacturer of all liability WARNING Only skilled specialists or trained personnel may perform repair work on electrical systems Before carrying...

Page 150: ......

Page 151: ...List of operators of the equipment Each operator of the equipment confirms here by his signature that he has received read and understood this user manual He agrees to comply with all instructions con...

Page 152: ...LIST OF OPERATORS OF THE EQUIPMENT CHAPTER 11 11 2 THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 Operator name Operator signature Accepted on Make further copies if required...

Page 153: ...re in a clear manner all maintenance and modification work performed and present the list to the supervisor for confirmatory signature This maintenance and modifications list should be made available...

Page 154: ...IFICATIONS LIST CHAPTER 12 12 2 THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 Confirmed by person responsible Operator signature Modification on Date Maintenance on Make further...

Page 155: ...IFICATIONS LIST CHAPTER 12 12 3 THP 94 42 R 4 XXT THP 125 42 R 4 XXT THP 140 H 42 R 4 XXT GB 07 2005 Confirmed by person responsible Operator signature Modification on Date Maintenance on Make further...

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