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Safetyregulations

2I

BP03_081_1701EN

2

Safety regulations

These  safety  regulations  conform  to  the  chapters  Terms,  definitions,
requirements"  and  Starting  up  and  working  with  the  machine"  in  the
German  Engineering  Federation  (VDMA)  brochure

Safety manual Concrete delivery and placing machines".

Here  you  will  find  a  summary  of  the  most  important  safety  regula
tions.  This  chapter  is  particularly  suitable  as  an  initial  basic  instruc
tion  for  new  employees.

Note

Special  safety  regulations  may  be  necessary  for  some  tasks.  These
special  safety  regulations  will  only  be  found  in  the  description  of  the
particular  task.

We include here a listing of regulations and safety standards for your
information:
EN 12001, Conveying, spraying and placing machines for con

crete and mortar

EN  12100,  Safety  of  machinery,
EN  60204−1,  Electrical  equipment  of  machines.
In  the  Federal  Republic  of  Germany:  DGUVRegulation101−012,

Concrete pumps and placing booms.

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Содержание BSA 1409 D4

Страница 1: ...ce staff always keep by the machine Stationary concrete pump BSA 1409 D4 Machine no 210110932 19 03 04 The paper on which this document is printed is 100 chlorine free E Putzmeister Concrete Pumps Gmb...

Страница 2: ...www putzmeister com tr USA PMA Putzmeister America 1733 90th Street Sturtevant WI 53177 USA 1 262 886 3200 1 262 886 3212 pmr putzam com www putzmeister com South Africa PMSA Putzmeister S A Pty Ltd...

Страница 3: ...za uporabu hu Eredeti zemeltet si tmutat ford t sa it Traduzione delle istruzioni d uso originali lt Eksploatavimo instrukcijos originalo vertimas lv Lieto anas pam c bas tulkojums no ori in lvalodas...

Страница 4: ...BP00_030_0911EN...

Страница 5: ...r 2 2 2 1 11 Machine operator 2 2 2 1 12 Hoseman 2 2 2 1 13 Signaller and other auxiliary personnel 2 2 2 1 14 Truck mixer driver 2 3 2 1 15 Subject expert 2 3 2 1 16 Qualified personnel 2 3 2 1 17 Af...

Страница 6: ...ns 2 18 2 7 Personal protective equipment 2 19 2 8 Before working with the machine 2 21 2 8 1 Checking that the machine is ready for operation 2 21 2 8 2 Rendering the machine ready for operation 2 21...

Страница 7: ...livery lines 2 41 2 13 3 Leak tightness and blockages 2 42 2 13 4 Opening delivery lines 2 43 2 13 5 Clearance to delivery lines 2 43 2 13 6 Fastening delivery lines 2 43 2 13 7 Continuation delivery...

Страница 8: ...3 14 3 4 6 Agitator 3 15 3 5 General conditions for using a concrete pump 3 16 3 5 1 Service life 3 16 3 5 2 Site of use 3 17 3 5 3 Height of job 3 17 3 5 4 Operating temperature 3 18 3 5 5 Centraliz...

Страница 9: ...up 4 1 Visual checks 4 1 4 1 1 Hydraulic system 4 1 4 1 2 Functional fluids 4 2 4 1 3 Condensate water 4 3 4 1 4 Lubrication points 4 3 4 1 5 Hydraulic fluid radiator 4 3 4 1 6 Water box 4 4 4 1 7 Pa...

Страница 10: ...1 6 F 80 chassis 5 5 5 1 7 Crawler track 5 7 5 1 8 Static base structure 5 7 5 2 Hand signals for driving 5 8 5 3 Requirements for the set up site 5 10 5 4 Setting up 5 14 5 5 Stationary delivery line...

Страница 11: ...8 Starting pumping 6 13 6 9 Pumping 6 14 6 9 1 Monitoring 6 15 6 9 2 Transfer tube damping 6 17 6 9 3 Blockages 6 18 6 9 4 Breaks in pumping 6 19 6 9 5 Engine 6 20 6 9 6 Overheating 6 20 6 9 7 Exhaus...

Страница 12: ...Glossary G 1 Symbols for concrete pumps in accordance with German Mechanical Engineering Association Standard VDMA 24119 G 1 G 2 Key to the symbols for concrete pumps G 7 G 3 Abbreviations and technic...

Страница 13: ...ill help you use these Operating Instructions Do not hesitate to contact us if you have any queries Putzmeister Concrete Pumps GmbH After Sales Department Max Eyth Stra e 10 D 72631 Aichtal Germany Te...

Страница 14: ...Guide to the Operating Instructions 1 X BP01_001_0802EN...

Страница 15: ...egulations for accident prevention and environ mental protection The Operating Instructions must always be available wherever the machine is in use These Operating Instructions must be read and applie...

Страница 16: ...acturer apply for this Modifications are made from time to time in the interests of constant improvement and it could be possible that we were unable to take these into consideration when these Operat...

Страница 17: ...ormal tools i e commercially available tools or tools carried in the truck are not specially listed Environmental protection Particular specifications regarding environmental protection are introduced...

Страница 18: ...possible to identify the source of the danger precisely Danger of fire This icon is used to identify actions for which there is a particular danger of fire Danger of explosion This icon is used to id...

Страница 19: ...with lethal consequences Danger of burning This icon is used to identify actions in which there is a danger of burning from chemical substances which are not specifically described Danger of burning T...

Страница 20: ...Guide to the Operating Instructions 1 6 AusgleichsseiteEN...

Страница 21: ...chapter is particularly suitable as an initial basic instruc tion for new employees Note Special safety regulations may be necessary for some tasks These special safety regulations will only be found...

Страница 22: ...Safety regulations 2 II BP03_081_1701EN...

Страница 23: ...ply to truck mixer concrete pumps Stationary concrete pumps Stationary placing systems an ensemble of placing boom and base structure For the purposes of this Safety Manual concrete pumps are de fined...

Страница 24: ...ety Manual Authorized representative of the owner of the concrete pumps and or placing booms The operator is responsible for the use of these machines Persons trained in and charged with the operation...

Страница 25: ...Safety Manual a subject expert is defined as a person who through their professional training their pro fessional experience and their recent professional activity has the required specialist knowled...

Страница 26: ...ions 2 4 BP03_082_1901EN 2 1 19 Place of work working area danger zone ab0005 14 6 7 1 2 3 5 6 8 9 10 11 12 Example ab0010 14 1 1 2 3 3 4 4 5 6 6 8 9 11 11 12 13 13 10 13 Example Mobile machines Stati...

Страница 27: ...of the placing boom 8 At the end hose Risk of injury when pumping is started during pumping operations when removing a blockage and during cleaning procedures The diameter of the danger zone is twice...

Страница 28: ...at operating elements for the agitator and truck mixer This requires a greater level of caution The truck mixer driver and machine operator must have visual contact The working area is the area in wh...

Страница 29: ...mixer driver If a place of work falls within the danger zone increased caution is required and suitable personal protective equipment is prescribed Persons who are auth orized to be present in such a...

Страница 30: ...ing out The diameter of the danger zone is twice the end hose length In the area of the hopper there is a risk of becoming trapped be tween the truck mixer and the hopper and of being sprayed with con...

Страница 31: ...exclusively for the delivery and placing of concrete up to a bulk density of 2400 kg m3 It must only be used for pumping operations on construction sites The maximum con crete pressure must not excee...

Страница 32: ...t consist of the following Retesting of the condition of the components and equipment with regard to the formation of cracks damage wear corrosion and other changes Retesting of the completeness and e...

Страница 33: ...ours meter records the hours of pumping operations The operating hours meter must always be kept in good working order It must not be tampered with For ma chines without an operating hours meter the o...

Страница 34: ...imum permissible gross weight may not be ex ceeded The placing boom must never be used for lifting loads wz0006 The placing boom must not be used under any circumstances to remove obstacles This would...

Страница 35: ...hose for example The quoted gross weight must not be exceeded If a longer end hose is used the diameter of the danger zone is also increased see also page 2 38 End hoses with a length of more than 4 m...

Страница 36: ...wz0026 In addition to this additional impermissible working areas exist de pending on the machine model and manufacturer which are de scribed in the Operating Instructions It is prohibited to climb th...

Страница 37: ...ns in particular use contrary to designated use incorrect operation maintenance and repair use of spare parts or accessories other than original manufac turer s spare parts and accessories or their eq...

Страница 38: ...ving parts All persons working on or with the machine must concentrate on the task at hand and not be distracted particularly by smartphones and music played through headphones Persons who are being t...

Страница 39: ...erstanding and application of the Operating Instructions and Safety Regulations and Safety Manual At regular intervals of at least once a year check that per sonnel are conscious of safety and the haz...

Страница 40: ...ise mandatory regulations relating to accident prevention and environmental protection Such regulations may also deal with handling hazardous substances the issuing and wearing of personal protective...

Страница 41: ...head against for instance falling con crete or parts of the delivery line in the event of a hose bursting DIN EN 397 Industrial safety helmets Safety footwear Safety footwear protects your feet agains...

Страница 42: ...ety harness When working at height use the climbing aids and working plat forms provided for reasons of safety or wear a safety harness The relevant national regulations must be complied with DIN EN 3...

Страница 43: ...lt fuel immediately Do not smoke or use a naked flame when handling fuel Set all the control and monitoring devices to the zero position be fore you change the mode of control control block control co...

Страница 44: ...outside in this discharge voltage pat tern If you step inside this discharge voltage pattern you will bridge different potentials This will cause a voltage corresponding to the potential difference to...

Страница 45: ...the unfolded placing boom if you wish to correctly estimate the movements of the boom and above all the clearance between the placing boom and obstacles or high voltage lines The same minimum clearanc...

Страница 46: ...idents can occur despite the use of a high voltage warning device You must therefore always maintain the minimum clearances mentioned above If despite all precautions a flash over occurs stay calm and...

Страница 47: ...transmitters must be earthed This earthing may be carried out by trained personnel Even when the machine is earthed the safe clearances to high voltage lines see also page 2 22 must be maintained and...

Страница 48: ...nditions may change as construction work prog resses Please also observe section 2 11 1 Mobile machines Set up site Stationary booms can be erected on tubular columns lattice booms or other base struc...

Страница 49: ...hat the assembled machine is working properly Only use suitable means to load and transport stationary machines Ensure that no one can be injured by the machine tipping over or slipping If there are t...

Страница 50: ...er ation of the machine Ensure that the set up site is adequately lit Do not set up the machine in areas where equipment may fall down Incidents of overlapping with the working areas of other machines...

Страница 51: ...or uneven ground The support area must be enlarged as required Support blocks and timber blocks may be used to increase the support area The support timbers must be undamaged and free from ice oil gre...

Страница 52: ...gle of 45_ Safe clear ance to the pits and slopes must be maintained and such clear ance must be determined in accordance with the nature of the ground The safe clearance is measured from the bottom o...

Страница 53: ...ding notes in this regard in the operating instructions Do not carry out more than one movement at a time If a movement is stopped the entire volume of fluid is available for the remaining movements a...

Страница 54: ...erload the slewing gear for the placing boom as well as its overall support structure jeopardising the stability of the machine wz0106 Check stability regularly during operation The elastic distortion...

Страница 55: ...hine must be safely stowed secured The maximum permissible gross weight must not be exceeded While the vehicle is being driven the delivery line pump and hopper must be empty If there is concrete resi...

Страница 56: ...on sloping terrain Observe national road traffic regulations If necessary clean the tyres lights and number plate Before travelling with the machine check that the braking steering signalling and ligh...

Страница 57: ...ppropriate means of transport and lifting equipment of adequate load bearing capacity Lifting equipment lifting tackle support trestles and other auxiliary equipment must be reliable and safe in opera...

Страница 58: ...out several movements at once requires an in creased level of attentiveness The range of a radio remote control is great enough for the machine to receive control commands e g from a great distance f...

Страница 59: ...rea This high ma noeuvrability means different placing booms can also be moved into dangerous positions Prohibited areas can be found in the Op erating Instructions There is a risk that you will damag...

Страница 60: ...started There is a risk of accident from the end hose swinging out or stones being ejected wz0136 If a longer end hose is used the diameter of the danger zone is also increased see also page 2 13 End...

Страница 61: ...concrete and so that concrete is directed pre cisely into the site of concrete placement Control the placing boom so that the hoseman can guide the end hose without power consumption The hoseman must...

Страница 62: ...ould fold in the placing boom if there is a risk of lightning strike Tower cranes on construction sites generally have wind speed measuring equipment enabling you to find out the wind speed at any tim...

Страница 63: ...r which varies according to the delivery pressure concrete composition the material from which the delivery line is made etc If you are not responsible for the separate delivery lines the per missible...

Страница 64: ...e e g by increasing the delivery pressure using compressed air etc There is a risk of death from the delivery line bursting or from concrete being ejected from the end of the delivery line Prevent blo...

Страница 65: ...g pumping operations Cordon off the danger zone If it is not possible to place a large enough cordon around the danger zone the delivery line must be covered by suitable means Delivery lines in partic...

Страница 66: ...are generally supplied with power by the hydraulic system of a machine It must therefore be possible to see between the devices and the machine with the con trol unit and vice versa Observe the Safet...

Страница 67: ...not endanger anyone s safety Refrain from any procedures that may impair the stability of the ma chine or are prejudicial to safety in any other way You must always carry the remote control on your p...

Страница 68: ...attached parts and the exhaust Never start work unless the grille is closed and bolted down or otherwise secured wz0225 Do not touch moving parts of the machine whether the machine is running or swit...

Страница 69: ...suspend operations until the defects are rectified As the machine operator it is your role to instruct the truck mixer drivers who deliver the concrete to you so that they are able to op erate the ope...

Страница 70: ...support legs must be fully re tracted and secured wz0156 The preferred methods for cleaning the delivery line are reverse pumping or forced cleaning with water The agitator must be switched on during...

Страница 71: ...he hose It could become entangled with moving machine components Take care when using aggressive cleaning agents Aggressive cleaning agents may attack materials e g rubber and painted sur faces You ca...

Страница 72: ...ut their length Reducer pipes must be drained and flushed out by hand No bends delivery or end hoses may be fitted at the end of the delivery line A catch basket must be fastened at the end of the del...

Страница 73: ...mpletely The dump cock must be opened in such a way that no one can be injured by concrete residue that might be expelled from the dump cock Water spraying on the machine from random directions has no...

Страница 74: ...Safety regulations 2 52 AusgleichsseiteEN...

Страница 75: ...hnical description This chapter describes the components and assemblies on this machine and describes how they function Please note that available options will also be described The machine card will...

Страница 76: ...General technical description 3 II BP02_001_0302EN...

Страница 77: ...ne 2 Engine see manufacturer s documentation 3 System for exhaust gas treatment 3 110 4 Hydraulic pumps 5 Condition of the suction filter 3 103 5 Suction filter 3 103 6 Pressure filter 3 103 7 Hydraul...

Страница 78: ...draulic indicators 3 103 3 Remote control 3 87 4 Machine rating plate 3 7 5 DEF container see manufacturer s documentation 6 Magnetic switch distributor casing 3 95 7 Buzzer Control block 8 Delivery c...

Страница 79: ...ton STOP button on the remote control 2 Covers over the switch cylinders 3 Side protection doors 4 Exhaust guard 5 Safety grille on the V belt 6 Transport protection 7 Securing bolts spring pins on th...

Страница 80: ...equipment 14 Sound proofing equipment sound proofing kit 15 Spray guard 16 Grille on the hopper Danger Never operate the machine if the safety equipment is not working You could injure yourself or ot...

Страница 81: ...Main pump hydraulic fluid pressure 360 bar Maximum concrete pressure rod side 71 bar Maximum concrete pressure piston side 106 bar Maximum output rod side 97 m3 h Maximum output piston side 67 m3 h M...

Страница 82: ...rective 2014 30 EU of the European Parliament and of the Council of 26 February 2014 The electromagnetic compatibility has been tested and meets the requirements set out under EN 13309 2010 12 Test re...

Страница 83: ...uid pressure in the hydraulic system bar 5 Year of manufacture 6 Maximum delivery pressure bar The following data depend on the machine model 7 Total weight kg 8 Delivery line diameter mm Note If spec...

Страница 84: ...he vicinity of the machine since the sound pressure level can be higher The sound pressure was determined on the basis of Directive 2000 14 EU The sound power level produced by the machine is given be...

Страница 85: ...given in dB A Disadvantage the actual sound pressure level is higher if you stand closer to the machine Nowadays the sound power level of the machine is stated To calcu late this an imaginary sphere o...

Страница 86: ...ne can be towed by a tractor unit if fitted with an F 8 chassis The chassis is unbraked and is designed for a maxi mum speed of 8 km h only The machine may therefore only be towed by a tractor unit on...

Страница 87: ...a tractor unit if fitted with a crawler track Note Observe the manufacturer s operating and maintenance instructions The machine is neither equipped nor approved for travel on public roads If your ma...

Страница 88: ...iven hydraulically by diesel engines or electric motors acting through fluid pumps The delivery pistons 3 are connected to the piston rods 1 of the drive cylinders by way of intermediate flanges The d...

Страница 89: ...piston forces 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 o...

Страница 90: ...f the concrete is very fluid and must only be pumped at low concrete pressure Transfer tube damping valve Note The transfer tube must switch over rapidly when pumping to great heights so that the swit...

Страница 91: ...on 1 Hydraulic motor 2 Agitator shaft 3 Agitator helix The filling rate in the delivery cylinders should be as high as possible when pumping This is achieved by having the agitator helix mix to wards...

Страница 92: ...ent spare parts and accessory components are used the service life is 15 years Truck mounted concrete pump standard Output m3 year 30000 Operating hours h year 400 Uses per day 3 Uses per year 750 Tru...

Страница 93: ...ve atmosphere Putzmeister must be contacted if the concrete pump is to be used at a height greater than that given here The standard reference level is the European standard elevation zero NHN Pump ty...

Страница 94: ...piston pump 15 50 Stationary concrete pump with diesel engine 8 45 Stationary concrete pump with electric motor Stationary boom 8 40 General rotor pump 3 40 Limited due to the diesel engine without p...

Страница 95: ..._789_1009EN 1 1a 3 5 6 1b 2 3 4 4 8 8 7 9 No 0 Designation 1a Lubricant reservoir 1b Lubricant pump 2 Grease gun 3 Lubricant distributor 4 Agitator shaft bearings 5 Transfer tube bearing 6 Supply line...

Страница 96: ...e Max marking through the filling nipple or from above through the filling opening Note Note the following when filling the lubricant reservoir Use only a grease listed in the lubricant recommendation...

Страница 97: ...time the S transfer tube switches over the lubricant distributor releases a drop of hydraulic fluid alternately through the upper or lower outlets to the lubrication points connected The dry running c...

Страница 98: ...ols used on the electrical con trol devices are described in one of the preceding sections The electrical control devices may include the following components depending on the equipment on your machin...

Страница 99: ...after treatment system 1 2 AP02_969_1508EN 1 3 4 5 6 Pos 0 Operating control element Meaning function Belongs to pos 1 Ergonic Graphic Display Displaying and setting operating states 2 Toggle switch...

Страница 100: ...Operating control element Meaning function Comments 1 Power socket 1 pin Connection for working light optional 2 Round socket 4 pin Connection for vibrator optional 3 Locally latched toggle switch Lo...

Страница 101: ...first pull it out and then push it towards the symbol The EMERGENCY STOP circuit is activated automatically when you switch over from local to remote control You must operate the horn to deactivate th...

Страница 102: ...open in an area with suffi cient distance from other machines combustible materials and flammable liquids The engine speed must be reduced to idling speed The delivery rate must be reduced to 0 The e...

Страница 103: ...On starts the regen eration procedure Once the regeneration procedure is complete you can only start up the pump again by following the procedure described below On the central module control cabinet...

Страница 104: ...r of interrupted regeneration procedures is logged in the control unit Note If you interrupt a regeneration procedure due to a yellow Regener ation warning symbol the exhaust after treatment system wi...

Страница 105: ...d appearance green background Function is active yellow background Limit reached warning red background Fault The fault must be remedied before the operation can be restarted on the machine black fram...

Страница 106: ...Graphic Display EGD Menu driven displays and adjustable functions are shown in the EGD 2 Push button HOME function key 3 Push button Help function key 4 Rotary push button Function button F4 for selec...

Страница 107: ...Use the rotary push button F4 to set the functions that can be se lected as follows Note In the Pump Status Pump Settings and Pump Counter menus you can select some functions and sensors using F4 The...

Страница 108: ...AP02_970_1410EN The following pages show the password free section of the menu structure example When the machine is set up HOME is dis played as the start screen for 5 seconds AP02_970_1410EN 1 1 2...

Страница 109: ...menu structure 5 Service Press F4 in HOME to display the Service menu 3 71 6 Pump status Press F1 in HOME to display the Pump status menu 3 41 7 Pump settings Press F2 in HOME to display the Pump set...

Страница 110: ...4_1104EN This test screen is displayed for 5 seconds as soon as the ignition is switched on BP22_944_1104EN 1 1 2 No 0 Display Function meaning 1 Version The software version number 2 Test screen Scre...

Страница 111: ...ion is not present AP02_971_1501EN 1 1 2 6 7 4 3 8 9 10 11 12 13 15 16 17 14 5 Pos 0 Display Function meaning 1 Temperature digital The temperature of the hydraulic fluid is displayed in numbers 2 Tem...

Страница 112: ...ue The current concrete pressure is displayed graphically The scale for the graphic display ranges from 0 to the maximum possible concrete pressure 10 Maximum concrete pres sure digital The set concre...

Страница 113: ...display the Service menu 15 Navigation symbol Press F3 to display the Pump flow meter menu 16 Navigation symbol and se lected control mode The Local control 0 remote control switch setting is displaye...

Страница 114: ...e concrete pump is switched off there may be a high concrete pressure in the delivery line e g due to a blockage for high rise pumping Exercise the necessary care when opening a delivery line even if...

Страница 115: ...Y STOP button has been operated Tank reserve optional Symbol lights up yellow if the tank content has fallen to less than 15 Hydraulic fluid radiator Symbol lights up green if the hydraulic fluid radi...

Страница 116: ...container content is between 10 and 5 The relevant message text is also displayed in the EGD Fill level warning symbol for the DEF container orange This symbol lights up orange if the container conten...

Страница 117: ...n of the pumping process in real time example shown here 2 Delivery direction An arrow indicates the direction of delivery 3 Transfer tube The switchover procedure is displayed graphically 4 Ammeter T...

Страница 118: ...trokes The number of strokes per minute is displayed 8 Stroke time The current stroke time is displayed 9 Engine speed The current engine speed is displayed Special features of the displays in the Pum...

Страница 119: ...ust then be adjusted manually The EOC function is switched off The engine speed is not limited The EPS control system calculates the deflection angle of the hy draulic pump using only the maximum engi...

Страница 120: ...ery rate to 50 and the hydraulic fluid radiator fans are switched on if the engine is running Cause of pump stoppage Symbol flashes if the pump has been stopped due to a fault In addi tion the cause o...

Страница 121: ...e number of the defective outlet is displayed see the follow ing table It is possible for instance that the magnetic coil of a hydraulic valve is defective This means that the associated outlet will b...

Страница 122: ...d off depending on the machine model Engine speed Resolver on the transfer tube switching shaft Magnetic switch Hydraulic fluid overheating High pressure Output current monitoring Pump centralized lub...

Страница 123: ...peed rpm delivery rate or stroke count F3 increases the parameter value depending on what was se lected engine speed rpm delivery rate or stroke count F4 Adjust settings switch functions on or off Not...

Страница 124: ...fluid as a precaution you can switch on the fan in the menu independently of the temperature hydraulic fluid radiator ON The factory settings of the EOC can be modified at any time by a Putzmeister se...

Страница 125: ...n meaning 1 Concrete pressure limit analogue The set concrete pressure limit is shown graphically and can be adjusted using the rotary push button F4 2 Concrete pressure limit digital The set concrete...

Страница 126: ...the case of local control the setpoint value of the delivery rate is shown in numbers as a percentage 9 Symbol By pressing F3 you can increase the parameter value depending on what was selected engine...

Страница 127: ...tched to External symbol plus arrow then the function can be switched on off by radio remote control EMERGENCY STOP The symbol lights up red if an EMERGENCY STOP button has been operated Agitator safe...

Страница 128: ...s in wear leads to a loss of warranty or guarantee claims Do not operate the machine if the display indicates a fault in the cen tralized lubrication system Note The number of operating hours in the c...

Страница 129: ...pressing it Push Over optional The function can be switched on off I 0 or switched to External using the function buttons When you switch on the Push Over function the delivery piston starts up quicke...

Страница 130: ...ntrol system can be switched over using the function buttons Conveying Symbol appears if the concrete pump is switched over to forward pumping or reverse pumping The operation mode can be switched ove...

Страница 131: ...d cylinder volume minus rod vol ume Since the cylinder is filled quickly the concrete pump runs more quickly and the delivery rate is greater The hydraulic pressure is however distributed over a small...

Страница 132: ...e type of drive for the delivery cyl inder AP02_980_1411EN 2 SBU software switch SBU switching between rod side and piston side feed Using the rotary push button F4 you can make use of the SBU soft wa...

Страница 133: ...controllers etc Technical data Rated voltage V DC 12 24 Operating voltage V DC 9 to 30 Max power consumption for the engine at 12 V A 6 5 Max power consumption for the engine at 24 V A 3 Lamp current...

Страница 134: ...he time between two lubrication procedures The interval time only runs down when the ignition is switched on The interval times are retained during interruptions The new times are added on restarting...

Страница 135: ...10 11 12 7 No 0 Display Function meaning 1 Setpoint value for the pump output The specified pump output is displayed 2 Actual value for the pump output The pump output achieved is displayed 3 Remainin...

Страница 136: ...are shown the values can be reset 8 Pump output display total The total pump output is displayed the value cannot be reset 9 Switch The pump flow meter can be switched on off I 0 10 Fill level The sp...

Страница 137: ...is achieved If you then switch the concrete pump off and on again the pump flow meter starts to count again from the specified setpoint value Note The pump flow meter is switched off in the works As...

Страница 138: ...he setpoint value flashes Now turn F4 to change the first digit Press F4 to store the changed setting of the first digit The second digit of the setpoint value flashes Go through all the digits of the...

Страница 139: ...he value The arrow flashes Now turn F4 to reset the value to zero Press F4 to store the changed setting The arrow is displayed in inverse video again The displayed numbers of strokes are calculated fr...

Страница 140: ...emains stored even when the ignition is switched off Amount of concrete in the truck mixer 8000 dm3 Number of strokes count the number of strokes until you have pumped the 8000 dm3 of concrete 160 Vol...

Страница 141: ...and fault messages are only active for engines with an electronic engine governor EMR AP02_982_1501EN 1 3 4 5 6 7 1 2 8 Pos 0 Display Function meaning 1 Operating hours digital The engine operating h...

Страница 142: ...ture analogue The cooling water temperature is displayed graphi cally Engine oil pressure digital The engine oil pressure is displayed in numbers 6 Engine oil pressure ana logue The engine oil pressur...

Страница 143: ...ult messages are shown using a numerical code in the display You can use the numerical code to identify the fault in the system description of the electronic engine governor The number before the deci...

Страница 144: ...or A warning is signalled by a fault indicator in the display and an acoustic warning if a horn is available If there is a fault it may lead to the pumping operations being stopped In order to continu...

Страница 145: ...ntent has fallen to less than 15 Battery charging control Symbol lights up red if the battery is not charged Engine oil pressure optional Symbol lights up red if the engine oil pressure is too low If...

Страница 146: ...ed In this menu the function buttons have no functions BP22_965_1105EN 1 1 2 3 4 No 0 Display Function meaning 1 Fault The fault code is displayed 2 Date The date of the fault events are displayed 3 S...

Страница 147: ...ected service area F4 adjust settings BP22_947_1104EN 1 1 No 0 Display Function meaning 1 Input field The password for the service area can be entered Caution Control system parameters can be set in t...

Страница 148: ...re versions of the control systems In this menu the function buttons have no functions BP22_946_1104EN 1 1 2 No 0 Display Function meaning 1 Software versions The software versions of the control syst...

Страница 149: ...us pumping conditions e g high density concrete Note As soon as no current is supplied to the control cabinet e g ignition off power take off off the settings are reset to the factory settings When th...

Страница 150: ...control if you set the EOC to the radio remote control position After starting the engine the engine speed stays at idling speed If the hydraulic fluid temperature is less than 25 C the delivery rate...

Страница 151: ...er 5 seconds 0 80 1600 rpm 80 1600 rpm maximum engine speed If the delivery rate is set to more than 80 the engine speed is in creased until the computed engine speed is reached but to no more than th...

Страница 152: ...ump or the other auxiliary units As soon as you switch off the water pump the engine speed is reduced to 850 rpm after 10 sec onds works setting If you should switch the water pump back on within thes...

Страница 153: ...ok for a set up site that has sufficient clearance to other machines combustible materials and flammable liquids Use your personal protective equipment Note The warning strategy of the SCR system comp...

Страница 154: ...nd 2 5 If DPF regeneration is required and shows escalation stage 1 If DEF quality and exhaust gas treatment are inadequate Power reduction stage 1 The engine torque is reduced by 25 see the engine ma...

Страница 155: ...tion stage 2 Power reduction level 2 is activated SER DIA service tool is required see also the documentation from the en gine manufacturer Warning symbol DPF regeneration running yellow Symbol lights...

Страница 156: ...y regener ation pumping operations stopped 3 Countdown display digital The time remaining for DPF regeneration in minutes is displayed in numbers 4 Message text The following message texts are display...

Страница 157: ...el warning symbol for the DEF container yellow This symbol lights up yellow if the container content is between 10 and 5 Fill level warning symbol for the DEF container orange This symbol lights up or...

Страница 158: ...e warning level is orange or red the power to the engine is reduced 2 Warning symbol Warning levels dark green light green yellow orange and red depending on the liquid level of the DEF container 3 Me...

Страница 159: ...quality products Observe the DEF quality warning symbols in the EGD these are displayed when sub standard DEF quality or a manipulated or de fective component has been detected Warning symbol for DEF...

Страница 160: ...nge or red the power to the engine is reduced 2 Warning symbol Warning levels depending on the DEF quality and ex haust gas treatment or in the event of DEF manipula tion yellow orange and red 3 Messa...

Страница 161: ...e The engine oil must be changed every 500 hours or after the DPF has been regenerated several times and if the warning symbol En gine oil change required is displayed AP02_975_1704EN 4 1 2 Example wa...

Страница 162: ...lustration Fill level of the DEF container Pos 0 Display Function meaning 1 Warning symbol Warning levels dark green light green yellow orange and red depending on the liquid level of the DEF containe...

Страница 163: ...le switch Engine On Off 4 Toggle switch Pump On 0 Reverse pumping 5 Toggle switch Deactivate EMERGENCY STOP change over 6 Toggle switch Increase Reduce engine speed 7 Toggle switch Ergonic Output Cont...

Страница 164: ...TOP activated symbol flashes on the Ergonic Graphic Dis play You may only start the pump up again as described below Unlock the EMERGENCY STOP button by turning it Operate the Deactivate EMERGENCY STO...

Страница 165: ...2 7 3 4 5 AP02_949_1508EN 1 No 0 Operating control element Meaning function 1 Toggle switch Acknowledging the agitator safety cutout 2 Toggle switch Pump Off 3 Toggle switch Agitator On agitation dir...

Страница 166: ...MERGENCY STOP button by turning it Operate the Deactivate EMERGENCY STOP toggle switch on the remote control Switch the pump off and then back on again using the Pump On 0 toggle switch on the remote...

Страница 167: ...positions of the EMERGENCY STOP but tons on your machine AP21_090_1701EN 1 EMERGENCY STOP button Note In order to trigger an EMERGENCY STOP on the machine you must press one of the EMERGENCY STOP butt...

Страница 168: ...main pump swings back and the delivery pistons stop The change over valve is de energized Note If the machine has an electrical agitator safety cutout the accumula tor dump valve is opened and the acc...

Страница 169: ...ble to switch over In addition the delivery pistons return to the end position and the concrete pump halts To restart the concrete pump you must first switch it off and then back on again In order tha...

Страница 170: ...re always check that the agitator safety cutout is working properly before using the pump The LEDs on the evaluation device indicate the following The green LED flashes for 8 seconds during the initia...

Страница 171: ...ellow LED Magnetic switch piston side drive cylinder II 3 4 Yellow LED Magnetic switch piston side drive cylinder I 4 5 Green LED In service lamp 5 There are two magnetic switches on each drive cylind...

Страница 172: ...ontinuously The distributor casing is ready for operation does not light up The Putzmeister operating system is not supplied with a voltage Note Additional LEDs are located on the magnetic switch conn...

Страница 173: ...ing diode These LEDs indicate the status of the connector and the magnetic switch 20500406 2 3 1 No 0 Designation 1 Green and yellow LEDs 2 Connector 3 Magnetic switch Note The yellow LED indicates th...

Страница 174: ...pportunity lights up continuously Magnetic switch is defective remove connector from the magnetic switch otherwise switchover is not possible and replace at earliest opportunity Green LED Connector an...

Страница 175: ...on the hydraulic control devices are described in one of the preceding sections The hydraulic control devices may include the following components depending on the equipment on your machine agitator...

Страница 176: ...al technical description 3 100 AP02_245_1402EN The water pump lever is used to switch the water pump on or off AP02_245_1402EN 1 1 2 No 0 Designation 1 Water pump off 2 Water pump on 3 7 1 Water pump...

Страница 177: ...f accident during special operation Special operation must only be carried out if You have been trained for these activities by the machine manu facturer You have been authorized for these activities...

Страница 178: ...control panel has failed you can use different directions of rotation to manually operate the agitator from the hydraulic control block illustrated below AP21_054_1609EN 1 1 1 Pos 0 Designation 1 Agit...

Страница 179: ...re gauge AP02_063_0308EN 1 The condition of the suction filter can be seen on the vacuum meter that of the pressure filter can be seen directly on the filter housing AP02_063_0308EN 2 Vacuum meter AP0...

Страница 180: ...istons are being replaced 5 1 2 3 4 No 0 Designation 1 Drive cylinder II 2 Ball valve for drive cylinder II 3 Ball valve for drive cylinder I 4 Drive cylinder I 5 Opened and secured ball valve Caution...

Страница 181: ...ther components are described in one of the preceding sections The following components may be described here depending on the equipment on your machine manual throttle lever for the engine flushing w...

Страница 182: ...or before it returns to the reservoir The hydraulic fluid radiator fan can be switched on and off manually on the control cabinet 20204201 2 1 3 4 No 0 Description 1 Control cabinet symbol for the hyd...

Страница 183: ...ro WP 50 generates a water pressure of 20 bar at a water delivery rate of 50 litres per minute maximum 11201701 1 3 4 5 2 6 No 0 Designation 1 High pressure water hose 2 Water pressure gauge 3 Pressur...

Страница 184: ...generates a maximum water pressure of 25 bar and a maximum water delivery rate of 160 litres per minute AP02_787_1008EN 1 1 2 3 5 4 No 0 Designation 1 Water pressure gauge 2 Connector for water hose 3...

Страница 185: ...ularly in the case of very stiff concrete The vibrator is electrically driven the connecting plug must be plugged into the appropriate socket on the control cabinet for this to work 31201000 1 2 3 4 N...

Страница 186: ...ment Caution It is not permissible to operate the engine using a different exhaust after treatment system It is not permissible to carry out unauthorized changes to the exhaust after treatment system...

Страница 187: ...bout how the exhaust after treatment system works Abbreviations used EAT Exhaust After Treatment after treatment of exhaust gas DEF Diesel Exhaust Fluid urea solution used in exhaust gas treat ment e...

Страница 188: ...le illustration SCR system Pos 0 Component 1 Engine control unit 2 Solenoid operated valve 3 Line heated with coolant to preheat the DEF container 4 DEF container 5 DEF delivery pump 6 DEF line 7 Line...

Страница 189: ...x emissions to nitrogen N2 and water H2O The engine control unit controls the DEF injection volume Caution Leaking DEF lines may cause damage to electrical and electronic components in the engine comp...

Страница 190: ...ion Catalyst Diesel Particle Filter DOC DPF module AP02_987_1702EN 2 1 2 3 4 Example illustration Diesel particle filter DPF Pos 0 Component 1 DOC diesel oxidisation catalyst 2 Exhaust gas temperature...

Страница 191: ...ration capabilities separates the soot created during the diesel fuel combustion pro cess The DPF must be regenerated as soon as it becomes increas ingly loaded with soot The passive diesel particle f...

Страница 192: ...rox 600 C Activate the regeneration procedure out in the open air only Select a set up site that has sufficient clearance from other ma chines combustible materials and flammable liquids Use your pers...

Страница 193: ...during en gine operation Actions inside the engine are enabled DPF soot load 62 Off Off None Passive regener ation 2 Heat mode 2 Required Passive regeneration takes place continuously during en Green...

Страница 194: ...n itiated manually by the machine operator DPF soot load 109 On On 25 Active regener ation Switch off step Regeneration using Service Tool required R ti i i iti t d b 50 of max torque d Red Regenerati...

Страница 195: ...ine for the first time and how to prepare your machine for use if left idle for a prolonged period Information is available on how to check your machine and how to carry out a test run with visual and...

Страница 196: ...Starting up 4 II AP13_015_0303EN...

Страница 197: ...sibility for the safety of anyone located in the machine s danger zone You are therefore under an obligation to ensure that the machine is com pletely safe in operation The fundamental prerequisite fo...

Страница 198: ...ou must therefore always wear personal protective clothing and equipment when you are handling toxic caustic or other functional fluids that are injurious to health and always take note of the manu fa...

Страница 199: ...under the drain cock to catch the escaping condensate water Open the drain cock Close the cock again as soon as fluid runs out Check that all lubrication lines are tight and free from fracture Check...

Страница 200: ...ly covered Check the water condition The drive cylinders are leaking if there is a clearly visible escape of fluid particularly at the piston rods At least one of the delivery pistons is worn if the a...

Страница 201: ...he inner wall of the pipe and its thrust ring for wear Reconnect the delivery line bend to the pressure connection Look into the hopper and check on the condition of the spec tacle wear plate and the...

Страница 202: ...net must not be closed once the engine has been switched on if this obscures the operating el ements Caution Damage to the engine caused by potential malfunctions in the fuel and exhaust after treatme...

Страница 203: ...t setting up and connection The engine can only be switched on when it is under no load i e there must be no consumers switched on AP13_106_1508EN 1 1 3 2 Example illustration No 0 Designation 1 Opera...

Страница 204: ...ay EGD Setting and displaying operating states 2 Locally latched toggle switch Local control 0 Remote control 3 Ignition starter switch Engine On Off Shift the toggle switch 2 on the control cabinet t...

Страница 205: ...he control cabinet or using the Diesel engine On Off toggle switch on the cable remote control Switch the pump on at the cable remote control using the Pump On Off Reverse pumping toggle switch Set th...

Страница 206: ...nd positions of the output controller AP13_026_0510EN 1 Checking the magnetic switches Check that the drive cylinders switch over automatically once the hydraulic pistons are close to the magnetic swi...

Страница 207: ...et the maximum pumping rate Start the measurement at the first switch over of the transfer tube The first single stroke is complete with the next transfer tube switch over Measure the stroke time over...

Страница 208: ...e able to switch off the machine quickly enough if danger threatens You must therefore check the functioning of the EMERGENCY STOP buttons each time you start work 10500200 Press lock EMERGENCY STOP T...

Страница 209: ...e transfer tube is switching A defective agitator safety cutout can cause you to believe that the machine is safe even though this is not really the case This can lead to the agitator continuing to ru...

Страница 210: ...ing head on the hopper example illustration Open the grille with the concrete pump running The transponder signal is broken The agitator must come to a halt immediately The transfer tube must no longe...

Страница 211: ...s switching A defective agitator safety cutout can cause you to believe that the machine is safe even though this is not really the case This can lead to the agitator continuing to run or the transfer...

Страница 212: ...g up 4 16 AP13_098_1402EN AP13_098_1402EN 1 1 Pos 0 Designation 1 Acknowledge agitator safety cutout in the operating panel Operate the Acknowledge agitator safety cutout toggle switch in the operatin...

Страница 213: ...e maximum pumping rate Note The indicators on the filters can only be checked under load once the hydraulic fluid has warmed up Please read the Filter change maintenance card 10300200 Vacuum meter Not...

Страница 214: ...filter if it is sticking up Note You must replace the filter element if the red button pops out again after a short time The filter is OK if the red button remains depressed Environmental protection...

Страница 215: ...safety cutout must be acknowledged before the concrete pump can be switched back on Before acknowledging the agitator safety cutout check that no one is in any danger 20203003 1 3 2 Pos 0 Designation...

Страница 216: ...longer be able to switch over safely 1 3 2 AP13_100_1402EN 1 Pos 0 Designation 1 Open gate valve 2 Gate valve Off 3 Close gate valve Switch the agitator off Set the output controller to min Check bot...

Страница 217: ...m a short function test lasting a few sec onds without the water being connected Note The agitator gate valve and flushing water pump can not be oper ated at the same time since they are all driven of...

Страница 218: ...f necessary clean it before operation Switch the agitator off and switch the gate valve to neutral On the operating panel 4 shift the Flushing water pump agitator set up foot toggle switch 3 to the Fl...

Страница 219: ...lectrical connection must first be made between it and the control cabinet 31201000 1 2 3 4 Check that the vibrator is functioning correctly Note The vibrator will only function when the switch for th...

Страница 220: ...the motor Note If you switch off the ignition the control unit for the electronic engine governor EMR4 is still supplied with power for approx two minutes During this run down time required data is s...

Страница 221: ...When you switch off the engine you must follow the instructions below Only switch off the engine using the ignition starter switch Do not unplug the control unit connector when the power supply is sw...

Страница 222: ...107_1508EN AP13_107_1508EN 1 1 Example illustration No 0 Designation 1 Ignition starter switch Engine On Off Switch off the ignition 1 The control unit saves required data during the run down time app...

Страница 223: ...ered by the warranty as stated in the general terms and conditions of DEUTZ Fault Cause Remedy Main relay switches to passive state Engine switched off as the battery is dis connected switched off DEU...

Страница 224: ...Starting up 4 28 AusgleichsseiteEN...

Страница 225: ...and connection 5 I AP06_001_1007EN 5 Transport setting up and connection This chapter contains information relating to transporting the ma chine Tasks required for setting up and connecting the machin...

Страница 226: ...Transport setting up and connection 5 II AP06_001_1007EN...

Страница 227: ...eyes will need to be fitted to the machine should you wish to load it onto a transport vehicle Any lifting eyes fitted to your machine for the purpose of lifting it will be located on the top of the m...

Страница 228: ...e machine standing on its support legs so that it cannot roll away AP06_003_1007EN 1 1 Suspend by all lifting eyes 1 Rope angle 45_ Hook a four cable sling to the 4 lifting eyes Danger The machine may...

Страница 229: ...AP06_003_1007EN Suspended load Use only appropriate lifting gear Suspend the BSA from the lifting eyes specified Never hoist the load over people Take note of the safety regulations for crane operatio...

Страница 230: ...icted to the construction site or private property Caution The machine must not exceed a maximum speed of 8 km h when under tow if fitted with an F 8 chassis You must load the machine onto a suitable...

Страница 231: ...ver of the tractor unit must have the relevant driving licence If you have to drive in reverse you must always ask for a signaller to guide you If necessary have the route cordoned off or secured by a...

Страница 232: ...is safe to drive lighting brakes tyre inflation pressures wheel nuts etc Clean the machine so that it does not soil the public roads Check that the accessories are secure Danger Supports extending sp...

Страница 233: ...ope and on ascending or descending routes You must load the machine onto a suitable transport vehicle to trans port it to the construction site see Loading Your machine can be towed by a tractor unit...

Страница 234: ...must be agreed between signaller and machine operator Below you will find some suggestions for hand signals to be used when driving Extend both arms out to the side 10000306 With the arm crooked point...

Страница 235: ...the direction the truck should drive 10000303 With the arm crooked wave the palm in the direction the truck should drive 10000304 With the arm crooked indicate the distance to an obstacle with the pa...

Страница 236: ...neration procedures stationary regener ation are regularly triggered automatically or if required activated manually Danger of fire Danger of fire due to inadequate clearance from a stationary con cre...

Страница 237: ...n all the guards flaps and hoods without obstruction Ensure that there is sufficient clearance around the entire ma chine The approach route must be sufficiently firm that so it can be driven over reg...

Страница 238: ...2102802 No voids or ground unevenness under the support feet Always rest the support feet on support plates timber blocks or other suitable construction timber It is recommended that you select a set...

Страница 239: ...f up to 12 tons is 1 metre Maintain a distance from pits slopes trenches etc when ap proaching the set up site The set up site must be adequately illuminated in order to ensure safe working on the mac...

Страница 240: ...site Drive the machine to the set up site you have inspected AP06_016_0110EN 1 Initial situation Use chocks to secure the machine against rolling Wind the support wheel down and disconnect the machin...

Страница 241: ...chine is sup ported AP06_016_0110EN 3 Supporting the rear Place timber blocks or other suitable material beneath the rear support feet Unlock the rear support feet by removing the spring pins from the...

Страница 242: ...ne by the drawbar sufficiently that the front support feet can be extended to exactly the same extent as the rear feet Place timber blocks or other suitable material beneath the front support feet Unl...

Страница 243: ...delivery line may be transmitted to the machine under extreme operating conditions high pressure delivery for example This recoil could jeopardize the stability of the machine The support feet can be...

Страница 244: ...d on the pump rating plate The delivery lines are subject to wear which is dependent upon the concrete pressure the concrete composition the delivery line material AP06_014_1007EN 1 10 9 8 7 5 4 3 2 6...

Страница 245: ...uries may be caused by the delivery line bursting as a re sult of a sudden increase in pressure Do not remain in the danger zone of a stationary delivery line Cover the stationary delivery line with a...

Страница 246: ...hout stresses Support the delivery line so that couplings can be easily fitted and removed Double wooden chocks see illustration are most suitable as they allow for longitudinal and latitudinal moveme...

Страница 247: ...e to the pump and vice versa Guide the delivery line in the direction of the arrow away from the concrete pump The operator s side of the concrete pump is then not in the danger zone Fit only as new d...

Страница 248: ...nary delivery line to reinforcements or scaf folding as these can be moved and could collapse If you wish to secure the stationary delivery line to reinforcements or scaffolding check whether the scaf...

Страница 249: ...e with a delivery pipe secured to it or sealed inside it It takes pump pulsa tions from the delivery line Install a fixed point near to the concrete pump The pump pulsations are reduced and the delive...

Страница 250: ...wnwards must always be fastened to the structure or background so that they are self supporting The delivery line must not be supported by the lowest pipe bend AP06_014_1007EN 8 Fastening the delivery...

Страница 251: ...livery line can be closed off so that the pressure bears on the gate valve and not on the concrete pump The delivery line is called a downpipe if it is laid in such a way that the concrete is pumped d...

Страница 252: ...een the individual pipes Note Grease all couplings and seals well internally before assembly Use a lithium soap base multipurpose grease with the marking K2K 4 mm AP06_014_1007EN 9 Putzmeister SK deli...

Страница 253: ...use delivery lines suitable for high pressure delivery if you are using piston side feed The procedure for changing the feed to the drive cylinders is as fol lows Shut the machine down and secure it...

Страница 254: ...cally degradable oils filters and auxiliary materials must be carefully collected and disposed of separately both from each other and from other waste Different categories of oil must also be kept sep...

Страница 255: ...ter pressure being too low for a significant head the hoses being pinched or kinked a damaged hose or several consumers using the same water supply at once AP06_056_1008EN 1 2 1 No 0 Designation 1 Cla...

Страница 256: ...06_056_1008EN 2 1 2 No 0 Designation 1 Claw coupling for high pressure water hose 2 Claw coupling for the water supply Note Make sure that you connect the flushing water pump with a sufficient supply...

Страница 257: ...ing operations 6 I AP07_026_9710EN 6 Pumping operations This chapter contains information regarding the operation of the machine for pumping You will learn what steps are required for pumping and clea...

Страница 258: ...Pumping operations 6 II AP07_026_9710EN...

Страница 259: ...machine is functioning the delivery line is designed to withstand the relevant concrete pressure and the delivery line is correctly laid Note If a malfunction occurs during the pumping operation you m...

Страница 260: ...when the machine is ready for operation If this is unavoidable in exceptional cases you must switch off the remote control disconnect it and lock it away Danger Risk to life from unintended machine mo...

Страница 261: ...ngable acoustic signals such as a horn two way radio field telephone etc optical signals such as light signals hand signals etc a combination of optical and acoustic signals Suggestions for the most i...

Страница 262: ...r it 10000327 The thumb of one hand points downwards The palm of the other hand is held under it 10000328 The crooked elbow of one arm points downwards into the palm of the other hand 10000329 Grip bo...

Страница 263: ...anufacturer s requirements and recommendations for func tional fluids Diesel engines equipped with SCR DPF and DOC types of exhaust after treatment systems must only be filled and operated with sul ph...

Страница 264: ...p yellow to prevent the engine power from being reduced Caution Damage to the SCR system caused by diesel exhaust fluid DEF impurities Impurities in other media e g diesel damage the SCR system Diluti...

Страница 265: ...otective equipment when handling diesel ex haust fluid Avoid skin contact with diesel exhaust fluid Any residue must be washed off with water Caution Corrosion damage and damage to electrical and elec...

Страница 266: ...Pumping operations 6 8 AP07_077_1501EN AP07_077_1501EN 1 1 2 Example illustration Filling the DEF container Pos 0 Designation 1 Fill level warning symbol for the DEF container yellow 2 DEF container...

Страница 267: ...Lid Switch off the remote controls Switch the pump off Switch the diesel engine off Secure the machine against being started up unintentionally Unscrew the lid 2 from the filler opening of the DEF co...

Страница 268: ...ciency of the pump i e the output per stroke 11000401 1 2 3 No 0 Description 1 Aggregate 2 Cement paste 3 Boundary layer Note A low fill level will be achieved in the delivery cylinder if the consist...

Страница 269: ...angerous as the compressed air is released suddenly at the end of the delivery line and the concrete can be blown out explosively No air must be sucked in for this reason You should therefore always f...

Страница 270: ...Pumping operations 6 12 AP07_050_0303EN AP07_050_0303EN 1 Caution The stop plates must be fitted in the water box during pumping operations 6 7 Inserting the stop plates...

Страница 271: ...ons 11000501 Starting pumping with thin concrete Insert two sponge balls into the delivery line through the wash out port Pour approximately 0 5 m3 thin concrete into the hopper Switch the agitator on...

Страница 272: ...ng admixtures must be mixed in for at least 4 minutes after they are added Pour the concrete from the truck mixer silo etc into the agitator hopper Switch the agitator on Begin delivery Note Start wit...

Страница 273: ...ressure gauge Check all displays for the monitoring instruments Vacuum meter the indicator must not be in the red zone An indi cator in the red zone implies that the associated vacuum filter is contam...

Страница 274: ...a fault is indicated All faults must be rectified immediately otherwise the guarantee will be invalidated Check the bearings and seals on the switching shaft the pres sure connection and the agitator...

Страница 275: ...control the switching speed of the transfer tube Note You must close the damping valve when you are pumping soft consistence concrete snail symbol as otherwise the transfer tube switches over too hars...

Страница 276: ...lines are leaking leavings in the transfer tube and delivery line unsuitable concrete composition segregated concrete set concrete Caution In the event of blockages pump the concrete immediately back...

Страница 277: ...r retentivity tendency to bleeding as the vibrations can segregate the concrete You must always leave the pump switched to reverse pumping when you begin pumping again and wait for the transfer tube t...

Страница 278: ...operation under high load high ambient temperatures too little fluid in the hydraulic system dirty hydraulic fluid radiator insufficient radiator ventilation hydraulic fluid radiator sucking in hot ex...

Страница 279: ...sary you can cool the drive cylinders with a water jet if the measures described above are not adequate 10600400 Direct the water jet at the drive cylinders and piston rods for the drive cylinders Cau...

Страница 280: ...after treatment sys tem Use your personal protective equipment Note For details on how to work and handle the exhaust after treatment system observe the engine manufacturer s documentation see the Exh...

Страница 281: ...off prevent the DPF regeneration procedure at the central module control cabinet as follows for example if the machine is located in a low building Press the Regeneration On Off toggle switch again o...

Страница 282: ...occur near a stationary con crete pump Activate the DPF regeneration procedure out in the open air only Look for a set up site that has sufficient clearance from other ma chines combustible materials...

Страница 283: ...s The engine speed must be reduced to idling speed The delivery rate must be reduced to 0 The engine must be in a no load state The engine must be warm coolant temperature higher than 70 C and exhaust...

Страница 284: ...the radiator must remain in operation Refresh the water in the water box Wait until the fluid has cooled if you are not able to find the fault immediately Once the red indicator lamp has extinguished...

Страница 285: ...of your machine you must observe the following Never use sea water or other water containing salt for cleaning purposes You must rinse off any sea water that is deposited on the machine Do not use an...

Страница 286: ...e recommend that you use the Putzmeister Leavings sheet to allow you to make use of the concrete leavings You can lay this down under the hopper before opening the hopper flap The con crete then flows...

Страница 287: ...hing or loss of limb by shearing if you reach inside It is prohibited to reach through the hopper flap into the hopper from below AP07_040_1009EN 1 Do not reach into the hopper Compressed air cleaning...

Страница 288: ...clean the delivery line and the concrete pump directly the site use is completed 10003401 1 2 3 4 1 Sponge pig 2 Sponge cube 3 Sponge ball 4 Wash out pig You will need sufficient numbers of sponge ba...

Страница 289: ...elivery line Danger A catch basket on the end of the delivery line is an absolute require ment if you are forcing the concrete out using compressed air as otherwise there is a risk of injury from the...

Страница 290: ...ete pump The cleaning connection can only be used for cleaning up to a maxi mum water or air pressure of 10 bar A catch basket on the end of the delivery line is an absolute require ment if you are fo...

Страница 291: ...quickly It traps the wash out sponge in suction cleaning AP07_041_9712EN 1 1 2 1 T delivery pipe with wash out port 2 Wash out port lid Danger Make sure that the T delivery pipe is also designed for...

Страница 292: ...oncrete flushing the concrete out and causing blockages 10003501 Rolled up cement bags Roll up 1 2 empty cement bags together Immerse the rolled up cement bags in water for about 5 minutes before star...

Страница 293: ...ystem includ ing the accumulator fully depressurized when you are measuring the hose length required as otherwise there is a risk of injury as the transfer tube switches over AP07_041_9712EN 2 1 1 Adh...

Страница 294: ...ck by the concrete pump from the site of concrete placement into the hopper Cleaning is backwards from the site of concrete place ment to the hopper The delivery line has been disconnected from the co...

Страница 295: ...elivery line Leavings from to Method of cleaning Compressed air Horizontal line Water under pressure Suction cleaning Compressed air only with special Riser Water under pressure special equipment Suct...

Страница 296: ...ng a water soaked wash out sponge Push a water soaked wash out sponge cube into the end of the delivery line at the site of concrete placement Switch the pump to reverse pumping The concrete and the w...

Страница 297: ...wash out sponge has passed the point at which you are tapping AP07_043_9712EN 2 Turn the wash out port lid round Open the wash out port on the T delivery pipe turn the wash out port lid round and clos...

Страница 298: ...ash out port and close the port or fit the pipe section pre pared for cleaning into the delivery line Hose down the hopper with water Fill the agitator hopper with water Switch the pump to Forwards pu...

Страница 299: ...r with high pressure water pump Note Any high pressure water pump you might be using must have a sufficient volumetric flow rate of water Pump out the agitator hopper as far as possible Switch the pum...

Страница 300: ...en using a high pressure water pump push two or three water soaked wash out sponges into the wash out port and then connect it to the delivery line Connect the water for the auxiliary pump or high pre...

Страница 301: ...rille to restart the concrete pump Danger In no event should you insert the water hose the spray gun or other objects through the grille into the hopper to spray out the delivery cylinders Such object...

Страница 302: ...avings out of the delivery cylinders into the hopper and thus out of the hopper opening 30000500 Hoisting the concrete away Caution You may only hoist a maximum of 0 5 m3 concrete approxi mately 1200...

Страница 303: ...ylinder with the concrete pump running slowly in reverse Allow the concrete pump to run slowly in reverse Spray the transfer tube out carefully downwards from the pres sure connection Slowly insert th...

Страница 304: ...r as the marking Hold the water hose in this position introduced as far as the marking for several minutes until only clean water runs out This will flush out the two delivery cylinders alternately Ca...

Страница 305: ...1 5 to 2 mm if not the transfer tube must be readjusted Maintenance card Adjusting the S transfer tube AP07_047_9904EN 4 S 2 3 4 1 1 Transfer tube 2 Thrust ring 3 Wear ring 4 Spectacle wear plate Chec...

Страница 306: ...eas that must be cleaned 3 Pressure connection 4 Lubrication points 5 Transfer tube bearing Carefully spray out the areas to be cleaned 2 on the pressure connection 3 and on the transfer tube bearing...

Страница 307: ...r tank and water pump must be drained fully if there is a risk of freezing The water box must also be drained at normal temperatures during longer breaks in pumping e g overnight and at weekends Leave...

Страница 308: ...y rinsing down with water At the lubrication point provided grease all of the bearing points in the hopper area immediately after washing it out Grease is visible on the lubrication point Grease all o...

Страница 309: ...g agent General Grease the untreated surfaces of mechanical parts rollers chains etc with Vaseline Rectify any corrosion damage Electrical system Disconnect the battery See the instructions on how to...

Страница 310: ...When you switch off the ignition the control unit of the electronic en gine governor EMR4 is still supplied with power for approx two minutes During this run down time required data is saved in the c...

Страница 311: ...I BP14_001_0501EN 7 Glossary This chapter illustrates the control system symbols icons for con crete pumps and explains the abbreviations and technical terms that are used in Putzmeister Operating In...

Страница 312: ...Glossary 7 II BP14_001_0501EN...

Страница 313: ...G 7 3701 3702 3703 3704 3705 3706 3707 3708 3709 3710 3711 3712 3713 3714 3715 3716 3717 3718 3719 3720 3721 3722 3723 3724 3725 4001 4002 4003 4004 5001 5002 5003 5004 5005 5006 5007 5008 6001 6002...

Страница 314: ...10 10011 10012 10013 10014 10015 10016 10017 10018 10019 10020 10021 10022 10023 10024 10025 11001 11002 11003 12001 12002 12003 12004 12005 12006 12007 12008 12009 12010 12011 12012 12013 12014 12015...

Страница 315: ...45 12046 12047 12048 12049 12050 12051 12052 12053 12054 12055 12056 12057 13001 13002 13003 13004 PM13005 PM13006 PM13007 14001 14002 14003 15001 15002 15003 G 1 2 Support for key see page G 10 2601...

Страница 316: ...1209 1210 1211 G 1 4 Boom 3 arm for key see page G 10 1301 1302 1303 1304 1305 1306 1307 1308 1309 1310 1311 1312 1313 1314 1315 1316 G 1 5 Boom 4 arm for key see page G 11 1401 1402 1403 1404 1405 14...

Страница 317: ...504 1505 1506 1507 1508 1509 1510 1511 1512 1513 1514 1515 1516 1517 1518 1519 1520 1521 1522 1523 1524 1525 1526 1527 1528 1529 1530 G 1 7 Boom 6 arm for key see page G 12 PM1601 PM1602 PM1603 PM1604...

Страница 318: ...M1403 PM1403A PM1404 PM1405 PM1406 PM1406A PM1407 PM1407A PM1408 PM1409 PM1410 PM1411 PM1412 PM1413 PM1414 G 1 10 Ergonic Boom Control 5 arm for key see page G 14 PM1501 PM1502 PM1502A PM1503 PM1503A...

Страница 319: ...3725 Screw conveyor 4001 Centralised grease lubrication manual 4002 Centralised grease lubrication automatic 4003 Centralised oil lubrication manual 4004 Centralised oil lubrication automatic 5001 Agi...

Страница 320: ...temperature 10005 Acknowledge cooling water excess temperature 10006 Engine oil pressure 10007 V belt failure 10008 Increase speed reduce speed 10009 Speed 10010 Speed sensor 10011 Increase speed 100...

Страница 321: ...e 12037 Left side 12038 Concrete brake 12039 Buzzer 12040 Container 12041 Position at the machine 12042 Lock 12043 2nd level 12044 Circuit 1 12045 Circuit 2 12046 Circuits 1 2 12047 High pressure limi...

Страница 322: ...e left 2616 Enable stability monitoring 2617 Stability monitoring G 2 3 Boom 2 arm 1201 Boom in general 1202 Arm 1 up 1203 Arm 1 down 1204 Arm 2 up 1205 Arm 2 down 1206 Boom activated 1207 Slew boom t...

Страница 323: ...1413 Move arms 1414 Move arms switched off 1415 Slewing gear activated 1416 Arms up switched off 1417 Slew boom to the left switched off 1418 Slew boom to the right switched off 1419 Arm 1 down switc...

Страница 324: ...Arm 1 down switched off 1521 Arms up switched on 1522 Tilt switch arm 1 circuit 1 1523 Tilt switch arm 1 circuit 2 1524 Tilt switch arm 2 circuit 1 1525 Tilt switch arm 2 circuit 2 1526 Pressure switc...

Страница 325: ...trol 4 arm PM1401 Move end hose PM1402 End hose forwards PM1402A End hose forwards USA PM1403 End hose back PM1403A End hose back USA PM1404 End hose up PM1405 End hose down PM1406 Unfold the placing...

Страница 326: ...ld the placing boom USA PM1508 End hose to the left PM1509 End hose to the right PM1510 Upper limit PM1511 Lower limit PM1512 Preferred position for arm 1 PM1513 Preferred position for arm 5 PM1514 Pr...

Страница 327: ...ivery cylinder to replace it B Blockage Blockage in the delivery line the concrete behind the blockage cannot continue to flow The blockage may occur due to wedging caused by coarse particles etc C Ch...

Страница 328: ...ve the placing boom using just one joystick Ergonic Graphic Display Graphic display in the control cabinet door The operating state of the machine is shown in the display You may also be able to set f...

Страница 329: ...ump to the drive cylinder using valves closed hydraulic circuit Functional fluids Hydraulic fluid fuel brake fluid battery acid etc G Grille The grille is the protective cover for the hopper and has t...

Страница 330: ...take off is a transmission dependent PTO The NMV power take off is independent of the clutch O One Side Support One Side Support is a type of support for supporting the machine in narrow spaces Operat...

Страница 331: ...uration Position of the M 31 arm assembly in Ergonic Boom Control operation when the end hose is moved within the stored limits Rotor pump The rotor pump comprises a rotor housing a rotor rotating abo...

Страница 332: ...hmic measurement for the relative loudness of the sound dB A Speed of rotation regulation The ADR function regulates the mixer drum speed while the truck is being driven Squeeze valve The squeeze valv...

Страница 333: ...be is a component which is swung between the two delivery cylinders in the hopper It is the connection between the delivery cylinder and the delivery line U UVD Umsteuer Verz gerungsdrossel Change ove...

Страница 334: ...Glossary G 22 BP14_002_0501EN...

Страница 335: ...find the most important key words with the number of the page on which you will find the key word as a heading in the left margin This Index of key words is listed alphabetically by the main concepts...

Страница 336: ...Index of key words 8 II...

Страница 337: ...38 T delivery pipe with wash out port 6 33 Wash out adaptors 6 32 With auxiliary pump 6 41 Cleaning agents 2 49 Clearances From high voltage lines 2 22 To delivery lines 2 43 Cold weather 2 40 Compon...

Страница 338: ...radiator 3 39 3 54 Magnetic switch 3 43 Menu independent warnings 3 77 Output current monitoring 3 45 Pump centralized lubrication system 3 39 3 45 Push Over 3 53 SBU switching between rod side and p...

Страница 339: ...12 Removing obstacles 2 12 Transporting goods 2 12 Inspection intervals 2 11 Instructions for laying the line Statio nary delivery line 5 20 L Liability Exclusion 2 15 Lifting eyes 5 2 5 3 Lifting lo...

Страница 340: ...25 Rod side piston side feed 5 27 S S transfer tube Description of the functions 3 13 Safety equipment 3 3 Safety footwear 2 19 Safety harness 2 20 Safety helmet 2 19 Selective Catalytic Reduction SC...

Страница 341: ...gitator safety cutout 4 15 V Vibrator 3 109 4 23 Visual checks 4 1 Condensate water 4 3 Functional fluids 4 2 Hydraulic fluid radiator 4 3 Hydraulic system 4 1 Lubrication points 4 3 Parts in contact...

Страница 342: ......

Страница 343: ...e staff always keep by the machine Stationary concrete pump BSA 1409 D4 Machine no 210110932 19 03 04 The paper on which this document is printed is 100 chlorine free E Putzmeister Concrete Pumps GmbH...

Страница 344: ...www putzmeister com tr USA PMA Putzmeister America 1733 90th Street Sturtevant WI 53177 USA 1 262 886 3200 1 262 886 3212 pmr putzam com www putzmeister com South Africa PMSA Putzmeister S A Pty Ltd...

Страница 345: ...za uporabu hu Eredeti zemeltet si tmutat ford t sa it Traduzione delle istruzioni d uso originali lt Eksploatavimo instrukcijos originalo vertimas lv Lieto anas pam c bas tulkojums no ori in lvalodas...

Страница 346: ...BP00_030_0911EN...

Страница 347: ...elding 2 4 2 4 Working on the placing boom 2 5 2 5 Safety relevant components 2 5 2 6 Software 2 6 2 7 Protective and safety equipment 2 6 2 8 Electrical power 2 7 2 8 1 General 2 7 2 8 2 Electrical c...

Страница 348: ...Agitator safety cutout 3 7 3 3 1 Description of the functions 3 8 3 3 2 Function check 3 9 3 3 3 Acknowledging the agitator safety cutout 3 11 3 4 Separating protective devices 3 12 3 4 1 Description...

Страница 349: ...2 Personnel requirements 5 7 5 3 3 Auxiliary devices 5 7 5 3 4 Residual risks 5 8 5 4 General tightening torques 5 10 5 4 1 Set screws and nuts 5 10 5 4 2 Flared screwed joint reassembly 5 11 5 4 3 Pr...

Страница 350: ...6 022 Change of delivery piston with APP 5 63 07 069 Replacing the transfer tube bearing 5 73 07 070 Replacing the switching shaft bearing flanged bearing 5 79 07 071 Replace the spectacle wear plate...

Страница 351: ...elp you to use these Service Instructions Do not hesitate to contact us if you have any queries Putzmeister Concrete Pumps GmbH After Sales department Max Eyth Str 10 72631 Aichtal Telephone 49 0 7127...

Страница 352: ...Guide to the Service Instructions 1 II BP01_009_1011EN...

Страница 353: ...ice Instructions must always be available wherever the ma chine is in use These Service Instructions must be read and applied by any person in charge of carrying out work with or on the machine e g in...

Страница 354: ...pply for the vehicle itself In the interests of constant improvement modifications are made from time to time and it may be the case that we were unable to take these into consideration when these Ser...

Страница 355: ...rmal tools i e commercially available tools or tools carried in the truck are not specially listed Environmental protection Particular specifications regarding environmental protection are introduced...

Страница 356: ...possible to identify the source of the danger precisely Danger of fire This icon is used to identify actions for which there is a particular danger of fire Danger of explosion This icon is used to ide...

Страница 357: ...ith lethal consequences Danger of burning This icon is used to identify actions in which there is a danger of burning from chemical substances which are not specifically described Danger of burning Th...

Страница 358: ......

Страница 359: ...ance and special work Note Special safety regulations may be necessary for some tasks These special safety regulations will only be found in the description of the particular task We include here a li...

Страница 360: ...Safety regulations 2 II BP03_083_1701EN...

Страница 361: ...y the machine manu facturer you have been authorized for these activities by the machine oper ating company We state here expressly that Putzmeister accepts no liability for dam age arising from incor...

Страница 362: ...ork If changes have been made to the machine it must be checked by a subject expert before recommissioning Secure a wide area around the maintenance area as far as is necessary A machine completely sh...

Страница 363: ...lean any traces of oil fuel or preservatives from the machine es pecially connections and threaded unions before carrying out maintenance or repair work Do not use aggressive cleaning ag ents Use lint...

Страница 364: ...ttach the earth cable of the welding unit directly to the component which is being welded The welding current must not flow through hinges cylinders etc Significant damage may be caused in the event o...

Страница 365: ...move the entire delivery line but rather replace it bit by bit e g replace the boom arm with a new boom arm Otherwise the pivot points of the new delivery line will have to be redetermined using speci...

Страница 366: ...for maintenance purposes must be refitted and checked immediately upon completion of this work All equipment required for safety and accident prevention warning signs and information plates grilles g...

Страница 367: ...olate adjacent live parts Disconnect the negative lead from the battery before starting any work on the electrical system of machines with an internal combus tion engine When reconnecting connect the...

Страница 368: ...the power supply The power on the construction site must be supplied from a special feed point construction site power distribution point Machines with an electric motor must not be connected to the m...

Страница 369: ...due to impaired blood circulation and infections Parts of the system and pressure lines which are to be opened hy draulic pneumatic and delivery lines must be depressurized ac cording to assembly des...

Страница 370: ...an cause in juries and fires During retesting hydraulic hoses must be checked by a subject expert for external damage The retest must be recorded in the check book The operator must have hydraulic hos...

Страница 371: ...ial When handling oils greases and other functional fluids observe the safety regulations applicable to the product concerned see the safety data sheet Oils fuel and other functional fluids may be haz...

Страница 372: ...To dispose of the machine you must proceed in accordance with all points in the disposal regulations which apply in your country During the disposal operation you must observe the following in particu...

Страница 373: ...I BP15_001_1202EN 3 Safety equipment The safety equipment on the machine is described in this chapter In particular it contains information about Intervals for inspection by subject experts Intervals...

Страница 374: ...Safety equipment 3 II BP15_001_1202EN...

Страница 375: ...for inspection by a subject expert Interval for function check EMERGENCY STOP function annually Before the machine is used each time Agitator safety cutout annually Before the machine is used each ti...

Страница 376: ...ied personnel with the necessary authorisation Safety related parts SRP are components that ensure the safety of the machine functions They are specially marked on spare parts sheets When a spare part...

Страница 377: ...clamation mark Safety related part SRP 3 Number Service life of the SRP years e g 10 10 years 4 Symbol Hourglass Service life of the SRP 5 Graphic Example illustration Spare parts sheet EB00 5 XXXXX X...

Страница 378: ...necessary authorisation 3 1 6 Parts with increased maintenance requirements The following listed parts are defined as parts with increased main tenance requirements This includes the following compone...

Страница 379: ...t components are present on the machine Area Safety action Pump The agitator stops The change over valve is de energized The accumulator dump valve is opened and the accumulator if fitted is emptied T...

Страница 380: ...tons are working properly Switch the pump and agitator on Press one of the EMERGENCY STOP buttons The agitator must come to a halt immediately The variable main pump swings back and the delivery pis t...

Страница 381: ...defective agitator safety cutout can cause you to believe that the machine is safe even though this is not really the case This can lead to the agitator continuing to run or the transfer tube switchin...

Страница 382: ...switch over In addition the delivery pistons return to the end position and the concrete pump stops AP15_005_1701EN 1 1 2 3 Pos 0 Designation 1 Reading head on the hopper example illustration 2 Green...

Страница 383: ...N 2 Open the grille with the concrete pump running The transponder signal is broken The agitator must come to a halt immediately The transfer tube must no longer switch over The concrete pump must run...

Страница 384: ...e transfer tube must no longer switch over Technical action The concrete pump must run to the end position and halt Note The LEDs on the evaluation device indicate the following information The green...

Страница 385: ...rating and the transfer tube is switching Before acknowledging the agitator safety cutout check that no one is in any danger Note You must acknowledge the agitator safety cutout on the operating panel...

Страница 386: ...ore the machine is used each time A protective device is an obstacle e g cover located between the machine operator and the danger zone Below you will see an example figure of a stationary concrete pu...

Страница 387: ...04_1701EN 1 1 2 3 4 6 5 7 Example illustration Pos 0 Safety equipment 1 Covers over the switch cylinders 2 Side protection doors 3 Exhaust guard 4 Grille on V belt depending on the machine 5 Water box...

Страница 388: ...at allows concrete with defined particle sizes to flow into the hopper The bars are subject to natural wear Danger If the grille is defective there is a risk that the operator could be caught in the a...

Страница 389: ...t H of the bars in an area with low wear the edge of the grille Compare the values measured Note You must have the grille replaced if one of the residual material thick nesses is less than 50 of the o...

Страница 390: ...re vented by means of the design Note You will find the locations of the plates on the machine circuit dia grams which indicate which plate should be affixed where 3 6 2 Function check Check whether t...

Страница 391: ...es are in particular Operation in situations of increased risk Operation with limited functions Danger There is an increased risk of accident during special operation Special operation must only be ca...

Страница 392: ...Special modes of operation 4 II AP16_001_1609EN...

Страница 393: ...ained for these activities by the machine manu facturer You have been authorized for these activities by the machine oper ating company To ensure that unauthorized persons are not able to gain access...

Страница 394: ...the emergency control lever Press the delivery cylinder emergency control lever to the left or right The corresponding delivery cylinder starts to move If the control system fails you can switch over...

Страница 395: ...ter pump lever must be in the zero position so that the fluid flow is directed to the agitator control block Note How the emergency operation devices are assigned may vary de pending on the mounting p...

Страница 396: ...AP16_002_1609EN 1 1 2 Example illustration Pos 0 Designation 1 Agitator on agitation direction away from the delivery cyl inder 2 Agitator on agitation direction towards the delivery cylin der To cha...

Страница 397: ...sk of accident during special operation Special operation must only be carried out if You have been trained for these activities by the machine manu facturer You have been authorized for these activit...

Страница 398: ...ontrol system is equipped with hydraulic control valves which can be operated by hand They are only for emergency man ual operation of the machine when the control system fails AP16_006_1701EN 1 1 2 P...

Страница 399: ...sfer tube switches over Pump the concrete out of the delivery line back into the hopper Clean the delivery line as described in the Cleaning section of the Pumping operations chapter Clean the hopper...

Страница 400: ...Special modes of operation 4 8 AusgleichsseiteEN...

Страница 401: ...ents includes a summary of the maintenance cards in numerical order you will find an alphabetical summary in the Index of key words under the entry for Maintenance cards We should like here to emphasi...

Страница 402: ...Maintenance 5 II BP09_001_9405EN...

Страница 403: ...devices available and in a fully functioning condition General Lubrication points sufficient lubrication Engine Oil level sufficient Agitator gearbox Oil level sufficient Oil level sufficient Hydrauli...

Страница 404: ...ine off fully functional All operating elements fully functional Vacuum meter for the suction filters in the green zone Red button for the pressure filters red button remains depressed Hydraulic syste...

Страница 405: ...ay escape from the bearings Hopper Mixer shaft bearings and seal from the bearings Instruments Monitor all in the normal range You should carry out the following service operations and checks after ev...

Страница 406: ...ecessary in the course of your daily checks Assembly Activity Maintenance card Replace the fluid filter Hydraulic system Replace hydraulic hoses Tighten change flared screwed joints Core pump Tighten...

Страница 407: ...year In addition a subject expert should inspect the pump and the delivery line Assembly Activity Maintenance card Check threaded unions General Output test Function test Full fluid change and clean f...

Страница 408: ...r clamping bolts Transfer tube Check the ball cups for the switch cylinders Check the switching shaft bearings and seals Check the pressure connection bearings and seals Agitator Change transmission o...

Страница 409: ...isted in the Safety regulations chapter Maintenance inspection and repair work must only be carried out by qualified personnel Qualified personnel means those who have completed specialist training fo...

Страница 410: ...rt snow and ice Danger In the area between the mixer drum and frame there is a risk of being pulled in crushed or injured by shearing Working in this area is only allowed if the mixer drum is secured...

Страница 411: ...ry from whipping hydraulic hoses Mechanically pre stressed hydraulic hoses may lash out when loosening the threaded union Wear your personal protective equipment Secure the hydraulic hoses tightly in...

Страница 412: ...n You must always use bolts of the same size and property class when you have to replace bolts Bolts with adhesive in the locking threads and self locking nuts must always be replaced after removal Yo...

Страница 413: ...120 10 L 45 20 S 250 12 L 55 25 S 400 12 S 80 30 S 500 15 L 70 38 S 800 RAD pipe external diameter MA tightening torque Tighten the union nut using a spanner While doing so you must use another spanne...

Страница 414: ...portant components in the WALFORMplus threaded union The next section describes what must be borne in mind during reassembly of WALFORMplus threaded unions BP09_022_1309EN 1 1 2 3 4 No 0 Designation 1...

Страница 415: ...and replace it if necessary For threaded unions made of rust proof steel grease the thread and the reshaped area of the pipes with an adequate amount of EATON ABF grease Pull the gasket onto the resha...

Страница 416: ...ALFORMplus threaded unions External diameter RAD Type MA Nm External diameter RAD Type MA Nm 6 L 30 18 L 110 8 L 35 22 L 140 10 L 40 28 L 210 12 L 55 35 L 300 15 L 80 42 L 400 RAD pipe external diamet...

Страница 417: ...draulic fluid HLP or biologically degradable hydraulic fluid based on a synthetic ester HEES or non readily flammable hydraulic fluid HFC see also http www putzmeister de deu Hydraulicfluids htm Pleas...

Страница 418: ...grades are mixed the new viscosity is determined by the mix ratio Loss of quality is poss ible if hydraulic fluids from different manufacturers are mixed For this reason you must always consult the ma...

Страница 419: ...use Do not store oils and greases in the open air Weather variations may cause water to be absorbed through the bung hole Only ever store the barrels lying on their side and supported on timber blocks...

Страница 420: ...ying out a full fluid change if your machine was filled with a synthetic ester in the works Putzmeister accepts no liability for damages caused by mixing fluids from different manufacturers You must f...

Страница 421: ...e power take off switch off the concrete pump and allow the machine to idle for a few minutes The machine should not be placed under full load until the tem perature of the hydraulic fluid VG46 has ri...

Страница 422: ...517 DIN 51 517 Characteristics synthetic mineral mineral see spare parts Viscosity grade NLGI Class CLP 220 CLP 220 CLP 220 p p sheet Material no 295246 006 000101 006 000101 006 Note Truck transmissi...

Страница 423: ...25 Characteristics mineral lithium soap Viscosity grade NLGI Class NLGI Class 2 DIN 51818 NLGI Class 1 DIN 51818 Material no 360000 009 360001 008 290207 008 Note We recommend the following grease rat...

Страница 424: ...Luxembourg Report Viscosities DIN 51519 ISO 3448 mm2 s ISO VG 32 46 68 46 46 Use 15_C to 80_C 10_C to 90_C 0_C to 95_C 10_C to 80_C 20_C to 60_C Particular char acteristics biodegrades quickly non re...

Страница 425: ...section you will find the maintenance cards necessary for this machine The table of contents includes a summary of the mainten ance cards in numerical order you will find an alphabetical summary in th...

Страница 426: ...Maintenance 5 24 BP09_013_1205EN...

Страница 427: ...er Safety regulations and the description of the Residual risks during maintenance inspection and repair work at the start of the chapter entitled Maintenance i e this chapter See also the maintenance...

Страница 428: ...lation on the electrical cables Timely detection and rectification of damage to the hydraulic system can prevent lengthy downtimes and high repair costs Check that the displays on the vacuum meter of...

Страница 429: ...tled Maintenance i e this chapter No further maintenance cards required The following special tools are required Pressure gauge and connections for the tapping points shown in the hydraulic circuit di...

Страница 430: ...Maintenance card 03 002 Page 2 of 2 5 28 WK03_002_1109EN...

Страница 431: ...SichV Please note any applicable regulations in your country of use Note There are specific risks of accidents associated with maintenance inspection and repair work For this reason read the chapter S...

Страница 432: ...has warmed up to its operating temperature of 50 _C to 70 _C The setpoint value for the accumulator pre charge pressure can be found on the hydraulic circuit diagram as item 120 and in the test readin...

Страница 433: ...y control lever 4 Transfer tube damping cock 5 Accumulator dump valve Note You can observe the pointer on the pressure gauge slowly going down as you slowly release the accumulator pressure Once the a...

Страница 434: ...he accumulator pressure is not dumped Operate the Transfer tube change over valve and dump the accumulator pressure slowly Note Depending on the direction in which you operate the emergency control le...

Страница 435: ...e with 2014 68 EU hydraulic fluids and nitrogen be long to the fluids in group 2 Directive 2014 68 EU appendix II diagram 2 applies The maximum permissible pressure PS the volume V in litres and the c...

Страница 436: ...d supervision institution no prescribed inspection period in accordance with BetrSichV Ordinance on Industrial Safety and Health Appendix 5 Number 2 For pressure equipment with gas cushions in hydraul...

Страница 437: ...caused by hydraulic fluid escaping under high pressure The risk exists if the hydraulic system is not depressurized before mainten ance work Always depressurize all lines before working on the hydraul...

Страница 438: ...Maintenance card 03 026 Page 8 of 8 5 36 WK03_026_1604EN...

Страница 439: ...ks Filter change Hoses No special tools required Note Cleanliness is of the utmost importance in the maintenance of hy draulic systems Prevent any type of dirt and contamination from entering the syst...

Страница 440: ...Dump the fluid pressure completely Danger Pressure stored in accumulators must be dumped Secure the machine against unauthorized starting Secure your working area and fix information plates to the loc...

Страница 441: ...be observed for these materials Open the cleaning port on the side of the hydraulic fluid reser voir Remove all filter elements Maintenance card Filter change Wipe out all the openings with a lint fr...

Страница 442: ...Use only the hydraulic fluids specified in the lubricant recommenda tion Remove the dirt deposits from the hydraulic fluid radiator Check all threaded unions and tighten where necessary Check all fla...

Страница 443: ...ead the chapter Safety regulations and the description of the Residual risks during maintenance inspection and repair work at the start of the chapter entitled Maintenance i e this chapter No further...

Страница 444: ...fferent categories of oil must also be kept separately from each other Nationally and regionally applicable dis posal regulations must be observed for these materials 10400800 Check hydraulic hoses Da...

Страница 445: ...onnection points with a plug immediately you have removed the old hydraulic hoses No dirt may enter the hy draulic circuit and the hydraulic circuit must not run empty Danger Hydraulic hoses should no...

Страница 446: ...flared screwed joints with the permitted tightening torque Tighten the flared screwed joints until you clearly feel an increase in the force required if you do not have a torque wrench available You m...

Страница 447: ...r work For this reason read the chapter Safety regulations and the description of the Residual risks during maintenance inspection and repair work at the start of the chapter entitled Maintenance i e...

Страница 448: ...Unscrew the old vacuum meter from the vacuum filter Screw the new vacuum meter onto the vacuum filter 10402000 Venting the vacuum meter Open the vent by either cutting off the tip of the packing piec...

Страница 449: ...o special tools required Note Replace the filter element once the indicator on the vacuum meter is in the red zone Cleanliness is of the utmost importance in the maintenance of hy draulic systems Prev...

Страница 450: ...filter elements in accordance with the relevant regulations The following tasks must be carried out before changing the filter Switch off the hydraulic pumps Switch off the engine motor Dump the flui...

Страница 451: ...04 012 Page 3 of 6 Maintenance card 5 49 WK04_012_1109EN WK04_012_1109EN 1 3 1 4 2 1 2 3 4 No 0 Designation 1 Lid 2 Hexagon nut 3 Plug 4 Drain cock Changing...

Страница 452: ...nuts 2 as far as the stop and remove the filter element without turning it to the stop 1 A shut off valve automatically interrupts the hydraulic fluid supply Open the upper plug 3 to provide an air s...

Страница 453: ...o the left and withdraw it from the magnetic rod 3 Wipe the magnetic rod 3 lengthways with a clean rag Note Before fitting new filter elements you must check all O rings and other seals on the filter...

Страница 454: ...wer edge of the lid to the tip of the filter element 10400401 K K Correction dimension Check and if necessary adjust the filter element to the correc tion dimension Caution The filtering process cause...

Страница 455: ...equired No special tools required The tightening torques can be found in the corresponding Spare parts list Note Cleanliness is of the utmost importance in the maintenance of hy draulic systems Preven...

Страница 456: ...eparately both from each other and from other waste Different categories of oil must also be kept separately from each other Nationally and regionally applicable dis posal regulations must be observed...

Страница 457: ...sed in at operating tempera ture WK04_013_1109EN 1 Checking and changing the pressure filter Bring the machine up to operating temperature 50 C Set the maximum engine motor speed Press the red button...

Страница 458: ...element 2 Filter housing Caution The filtering process causes dirt and contamination particles to accumulate in the filter housing You must therefore clean the filter housing thoroughly before refitt...

Страница 459: ...ith a cleaning rag Install a new filter element Note Before fitting new filter elements you must check all O rings and other seals on the filter elements and replace them if damaged Screw the filter h...

Страница 460: ...Maintenance card 04 013 Seite 6 von 6 5 58 WK04_013_1109EN...

Страница 461: ...n and repair work at the start of the chapter entitled Maintenance i e this chapter No further maintenance cards required No special tools required Danger Risk of injury from rotating and hot componen...

Страница 462: ...rs whichever is soonest Refer to the engine manufacturer s documentation for details about maintenance of the exhaust after treatment system Environmental protection You must carefully collect the fil...

Страница 463: ...04 019 Page 3 of 4 Maintenance card 5 61 WK04_019_1709EN WK04_019_1709EN 1 1 2 3 4 2 Pos 0 Designation 1 DEF delivery pump 2 Lid 3 Compensating device 4 Filter element DEF delivery pump...

Страница 464: ...l connection Place a suitable container under the DEF delivery pump 1 so you are able to collect escaping diesel exhaust fluid Unscrew the lid 2 Pull out the filter element 4 and the compensating devi...

Страница 465: ...ks of an accident associated with maintenance inspection and repair work For this reason read the chapter Safety regulations and the description of the Residual risks during main tenance inspection an...

Страница 466: ...the fluid pres sure in the hydraulic system has been reduced Open the accumulator dump cock on machines with an accu mulator Close the accumulator dump cock as soon as you can see on the pressure gaug...

Страница 467: ...ove the stop plates in the water box As the delivery pistons are changed from below the base must also be removed Shut the machine down Remove the water box cover Remove the two stop plates from the w...

Страница 468: ...ders in the end position in order now to be able to withdraw the delivery pistons from the delivery cylinders You must close both stroke correction lines to do this 20202301 The works fits the APP iso...

Страница 469: ...302 1 2 1 As fitted position secured against rotation 2 Rotate position Undo the bolt on the handle and remove the handle Lift up the guide washer and refit it rotated through 90_ Replace the handles...

Страница 470: ...tch the concrete pump off when the drive cylin ders have reached their dismantling end position Then you can release the Change over switch Shut the machine down WK06_022_1109EN 2 1 4 2 5 3 1 Hexagon...

Страница 471: ...y now replace the worn components on the dismantled delivery piston WK06_022_1109EN 3 1 2 3 4 5 1 Hexagon head bolt 2 Flange 3 Delivery piston seal 4 Guide ring 5 Piston body Replace the worn parts Gr...

Страница 472: ...as reached its dismantling end position Note Replace the second delivery piston in the same way 20202301 Open the isolating valve and secure it against rotation Open the two isolating valves when deli...

Страница 473: ...ion 2 Rotate position Replace the guide washer so that it is blocked in position fit the handle and bolt it down Fit the base with its water outlet to the water box Fill the water box with water and c...

Страница 474: ...Maintenance card 06 022 Page 10 of 10 5 72 WK06_022_1109EN...

Страница 475: ...the chapter en titled Maintenance i e this chapter No further maintenance cards required No special tools required The tightening torques can be found in the corresponding Spare parts list Danger of c...

Страница 476: ...erform all machine functions using the remote control Proceed as follows to shut down the machine Switch off the engine Dump the pressures completely Danger Dump the accumulator pressure completely in...

Страница 477: ...ble lifting gear to the S transfer tube Remove the lubrication lines from the transfer tube bearing Undo the nuts on the pressure flange Remove the pressure flange and withdraw the pressure con nectio...

Страница 478: ...ponding spare parts sheet Grease the new gasket set Bend the grooved ring to make installation easier Insert the gasket set as shown on the spare parts sheet Note Clean the transfer tube bearing befor...

Страница 479: ...9_1109EN 3 Note Pay attention to the location of the lubrication openings when fitting the transfer tube bearing Fit the transfer tube bearing and the pressure connection again and bolt them both in p...

Страница 480: ...Maintenance card 07 069 Page 6 of 6 5 78 WK07_069_1109EN...

Страница 481: ...nce inspection and repair work at the start of the chapter en titled Maintenance i e this chapter See also the maintenance cards Adjusting the S transfer tube No special tools required The tightening...

Страница 482: ...ed out the machine must have been shut down The operations necessary for this task are described below and must be carried out conscientiously Perform all machine functions using the remote control Pr...

Страница 483: ...concrete pump proceed as follows Unlock the EMERGENCY STOP button and sound the horn Switch the engine on Caution Do not switch the pump on until you are called upon to do so When you are starting up...

Страница 484: ...for ball cup 2 Ball cup 3 Hydraulic port 4 Plunger cylinder 5 Retaining plate 6 Retaining plate fastening bolts 7 Switch lever 8 Clamping bolts with nuts 9 Disc 10 Switching shaft 11 Hexagon nut 12 F...

Страница 485: ...e machine down Remove any lubrication lines from the retaining plate 5 and flanged bearing 12 WK07_070_1109EN 2 Unbolting the retaining plate Screw the fastening bolts 6 out of the retaining plate 5 a...

Страница 486: ...and from other waste Different categories of oil must also be kept separately from each other Nationally and regionally applicable dis posal regulations must be observed for these materials Place an o...

Страница 487: ...cylinder 1 out of the ball cup 3 from the piston side as shown If the ball cup is worn you can screw a bolt into the pulling bore 4 for the ball cup and press out the plunger cylinder with the ball c...

Страница 488: ...y Unscrew the hexagon nut and remove it from the switching shaft and remove the washer Note If the switch lever has a slot this means that the switch lever is fitted with clamping bolts and a pulling...

Страница 489: ...slotted If available unscrew and remove the clamping bolts 1 from the switch lever 2 Note One of the holes 5 for the clamping bolts 1 is also the pulling bore for the switch lever 2 If required force...

Страница 490: ...ally opposite each other 3 Flanged bearing Unscrew the fastening bolt 1 from the flanged bearing 3 Attach suitable lifting gear to the S transfer tube Press out the flanged bearing 3 by turning the tw...

Страница 491: ...70_1109EN WK07_070_1109EN 7 Removing the retaining ring Remove the retaining ring WK07_070_1109EN 8 Removing the old grooved ring Remove the old gasket set To do this you may have to cut open the ring...

Страница 492: ...d ring Clean the flanged bearing Grease the new gasket set Caution For the mounting position of the grooved ring in the flanged bearing please refer to the accompanying spare parts sheet Insert the ga...

Страница 493: ...g 2 so that the tab 5 is located in the bore 4 thereby securing the washer against rotation Insert the wear sleeve 1 into the flanged bearing 2 Note Note the location of the lubrication bores when fit...

Страница 494: ...ned tooth 7 Notch Grease the teeth on the switch lever 1 and the switching shaft 2 with Anti Seize AS 450 assembly paste or equivalent as sembly grease Fit the switch lever 1 so that the flattened too...

Страница 495: ...zed lubrication system grease gun Insert the plunger cylinder Note The hydraulic system must be bled once assembly is complete if you have removed the hydraulic hoses from the plunger cylinders Do thi...

Страница 496: ...Maintenance card 07 070 Page 16 of 16 5 94 WK07_070_1109EN...

Страница 497: ...isks during main tenance inspection and repair work at the start of the chapter en titled Maintenance i e this chapter See also the maintenance cards Replacing the transfer tube bearing Replacing the...

Страница 498: ...may result in you being seriously injured if you are working on the machine To avoid risk shut the machine down and secure it against unauthorized or accidental starting Caution Use only suitable lift...

Страница 499: ...ump the accumulator pressure completely in systems with pressure accumulators The machine may be started up differently depending on the ma chine model When you are starting up a truck mounted concret...

Страница 500: ...4 of 14 5 98 WK07_071_1109EN WK07_071_1109EN 1 1 2 3 4 5 1 6 6 6 No 0 Designation 1 Plunger cylinder 2 Switch lever 3 Clamping bolts with nuts 4 Switching shaft 5 Hexagon nut 6 Fastening bolts for sp...

Страница 501: ...switch lever 2 Maintenance card Replacing the switching shaft bearing flanged bearing WK07_071_1109EN 2 Pushing the S transfer tube to one side Note If there is not enough space available for assembly...

Страница 502: ...rd 07 071 Page 6 of 14 5 100 WK07_071_1109EN WK07_071_1109EN 3 2 3 4 5 1 1 2 No 0 Designation 1 Transition liner 2 Intermediate ring 3 Screw plug 4 Lubrication nipples 5 Grease gun Replacing the inter...

Страница 503: ...sition liner 1 using the lubrication nipple 4 from the accessories Connect a grease gun 5 to the lubrication nipple 4 Keep pumping in grease until the intermediate ring 2 is pressed out WK07_071_1109E...

Страница 504: ...5 1 3 2 No 0 Designation 1 Intermediate ring 2 O rings 3 Transition liner Slide in two O rings 2 over the mounting surface of the new intermediate ring 1 Grease the mounting surface of the new interme...

Страница 505: ...to the transition liner 3 Replace the second intermediate ring 1 in the same way WK07_071_1109EN 6 Fitting the O ring Insert one O ring 2 into the recess at the front of the inter mediate ring 1 The f...

Страница 506: ...14 5 104 WK07_071_1109EN WK07_071_1109EN 7 1 3 4 2 1 5 6 7 No 0 Designation 1 Fastening bolts on the left and right 2 Spectacle wear plate 3 Fastening bolts at the top and bottom 4 Intermediate ring...

Страница 507: ...ew spectacle wear plate 2 Using the fastening bolts on the left and right 1 screw on the new spectacle wear plate 2 finger tight Note If you have a ceramic spectacle wear plate 2 please contact our Af...

Страница 508: ...y use the screw plugs and not the lu brication nipples Otherwise there is a risk that you will accidentally lubricate these lubrication nipples as well while lubricating the ma chine Over time this wo...

Страница 509: ...cing the thrust ring and wear ring Fit the transfer tube bearing Maintenance card Replacing the transfer tube bearing Insert the plunger cylinder Maintenance card Replacing the switching shaft bearing...

Страница 510: ...Maintenance card 07 071 Page 14 of 14 5 108 WK07_071_1109EN...

Страница 511: ...of the Residual risks during main tenance inspection and repair work at the start of the chapter en titled Maintenance i e this chapter See also the maintenance cards Replacing the transfer tube bear...

Страница 512: ...equipment for lifting components Note Wear parts must be replaced in the event of one of the following Severe wear is visible Concrete is seeping out We recommend that the switch lever also be replace...

Страница 513: ...ump the accumulator pressure completely in systems with pressure accumulators The machine may be started up differently depending on the ma chine model When you are starting up a truck mounted concret...

Страница 514: ...ansfer tube is fitted the recommended pro cedure for dismantling is as described below The S transfer tube with bolted switching shaft may also be dismantled and reassembled in the hopper The tube is...

Страница 515: ...all thickness of the double layer pipe Shut the machine down Attach suitable lifting gear to the S transfer tube Remove the transfer tube bearing Maintenance card Replacing the transfer tube bearing R...

Страница 516: ...fer tube forwards until the transfer tube outlet is free Lift the S transfer tube outlet opening first upwards and out Note If just the wear sleeve is heavily worn you can also replace just the wear s...

Страница 517: ...thrust ring and wear ring Fit the switching shaft bearing flanged bearing Maintenance card Replacing the switching shaft bearing flanged bearing Fit the transfer tube bearing Maintenance card Replacin...

Страница 518: ...Maintenance card 07 072 Page 8 of 8 5 116 WK07_072_1109EN...

Страница 519: ...ce inspection and repair work For this reason read the chapter Safety regulations and the description of the Residual risks during main tenance inspection and repair work at the start of the chapter e...

Страница 520: ...may result in you being seriously injured if you are working on the machine To avoid risk shut the machine down and secure it against unauthorized or accidental starting Caution Use only suitable lift...

Страница 521: ...ump the accumulator pressure completely in systems with pressure accumulators The machine may be started up differently depending on the ma chine model When you are starting up a truck mounted concret...

Страница 522: ...this Shut the machine down Remove the transfer tube bearing Maintenance card Replacing the transfer tube bearing Loosen the hexagon nut on the switching shaft and the clamp ing bolts on the switch lev...

Страница 523: ...n fitted proceed as follows Weld a metal pin onto the wear sleeve Caution When cutting open the welds take care not to damage the S transfer tube Carefully cut open the welds 1 on the front face betwe...

Страница 524: ...Caution When cutting open the welds and wear sleeve take care not to dam age the S transfer tube Carefully cut open the welds 1 on the front face between the S transfer tube outlet 2 and wear sleeve 3...

Страница 525: ...chrome plated and must not therefore be heated unevenly or too intensively Heat up the new wear sleeve 1 evenly to approx 140 _C Place the heated wear sleeve 1 over the tube outlet 2 and allow the wea...

Страница 526: ...1109EN Fit the transfer tube bearing Maintenance card Replacing the transfer tube bearing Tighten the hexagon nut on the switching shaft and the clamp ing bolts on the switch lever Maintenance card Re...

Страница 527: ...work For this reason read the chapter Safety regulations and the description of the Residual risks during main tenance inspection and repair work at the start of the chapter en titled Maintenance i e...

Страница 528: ...may result in you being seriously injured if you are working on the machine To avoid risk shut the machine down and secure it against unauthorized or accidental starting Caution Use only suitable lift...

Страница 529: ...ump the accumulator pressure completely in systems with pressure accumulators The machine may be started up differently depending on the ma chine model When you are starting up a truck mounted concret...

Страница 530: ...ing Maintenance card Replacing the transfer tube bearing Loosen the hexagon nut on the switching shaft and the clamp ing bolts on the switch lever Maintenance card Replacing the switching shaft bearin...

Страница 531: ...proceed as follows Clean the thrust ring seat 1 thoroughly Dirt and concrete resi due must be removed from the seat Fit the new thrust ring 1 and new wear ring 2 into the S transfer tube Fit the tran...

Страница 532: ...Maintenance card 07 074 Page 6 of 6 5 130 WK07_074_1109EN...

Страница 533: ...ks of an accident associated with maintenance inspection and repair work For this reason read the chapter Safety regulations and the description of the Residual risks during main tenance inspection an...

Страница 534: ...may result in you being seriously injured if you are working on the machine To avoid risk shut the machine down and secure it against unauthorized or accidental starting Caution Use only suitable lift...

Страница 535: ...p the accumulator pressure completely in systems with pressure accumulators The machine may be started up differently depending on the ma chine model When you are starting up a truck mounted concrete...

Страница 536: ...1 2 3 4 5 6 7 9 8 No 0 Designation 1 Spectacle wear plate 2 Wear ring 3 S transfer tube 4 Thrust ring 5 Gap 6 Hexagon nut 7 Retaining plate 8 Switch lever 9 Clamping bolts Note Make sure that the thr...

Страница 537: ...t ring 4 is then compressed by 1 5 mm The gap 5 between the S transfer tube 3 and wear ring 2 is set Ensure that one surface on the hexagon nut 6 is horizontal at the top so that the retaining plate 7...

Страница 538: ...er tube must not be either too great or too small WK07_075_1109EN 2 1 2 3 No 0 Designation 1 Swing angle too great 2 Swing angle too small 3 Optimum swing angle The left hand switching overlap is corr...

Страница 539: ...7 WK07_075_1109EN WK07_075_1109EN 3 1 2 3 No 0 Designation 1 Plunger cylinder 2 Ball cup 3 Packing washer Start the machine up WK07_075_1109EN 4 Plunger cylinder extended Allow one plunger cylinder to...

Страница 540: ...late Use a felt tip pen or oil chalk to mark the position of the wear ring on the spectacle wear plate Start the machine up Allow the other plunger cylinder to retract Shut the machine down Determine...

Страница 541: ...r too thick 3 Optimum packing washer To decrease the swing angle of the S transfer tube by 4 mm the fitted packing washer must be replaced by one which is 2 mm thicker To increase the swing angle of t...

Страница 542: ...Locking plate Remove the locking plate 2 of the extended plunger cylin der 1 10300800 Removing the plunger cylinders Note The plunger cylinders can be pushed back as illustrated It is how ever also po...

Страница 543: ...2 No 0 Designation 1 Ball cup 2 Packing washer Remove the hexagon ball cup 1 along with the packing washer 2 Caution No packing washers 2 may be inserted in the switch lever as other wise the plunger...

Страница 544: ...late and correct accordingly The two plunger cylinders must extend to the same extent on ma chines with fully hydraulic control VHS and active signal tapping in the plunger cylinders 20300703 Plunger...

Страница 545: ...rements E1 and E2 should be identical You will have to change the packing washers as described below if the two measurements are not equal Swap the packing washer on the plunger cylinder with the grea...

Страница 546: ...Maintenance card 07 075 Page 14 of 14 5 144 WK07_075_1109EN...

Страница 547: ...e a day Hinweis There are specific risks of an accident associated with maintenance inspection and repair work For this reason read the chapter Safety regulations and the description of the Residual r...

Страница 548: ...ized lubrication nipple strip 3 Lubrication nipple for the lower bearings on the switch cylinder Lubricate each lubrication nipple with a grease gun until clean grease exits from the lubrication point...

Страница 549: ...aintenance inspection and repair work For this reason read the chapter Safety regulations and the description of the Residual risks during main tenance inspection and repair work at the start of the c...

Страница 550: ...e starting on large jobs You will obtain reliable results for your measurements if you carry out the test with the measuring device recommended by Putzmeister Danger of explosion The delivery line can...

Страница 551: ...ammer handle Uniform wear can be achieved by regularly rotating the straight de livery pipes through 120 The minimum wall thickness for straight pipes is shown in the graph below Uniform wear can be a...

Страница 552: ...We should draw your attention to the fact that the S transfer tube is subject to varying loading as a result of the dynamic loading during pumping There is no general method for calculating the minimu...

Страница 553: ...s less than the minimum wall thickness Note As a rule it is possible to continue pumping with an operating pres sure lower than that shown in the graph We should however draw your attention to the fac...

Страница 554: ...Maintenance card 10 007 Page 6 of 6 5 152 WK10_007_1109EN Minimum wall thickness as a function of operating pressure 1 2 1 High pressure 2 Maximum delivery pressure Graph...

Страница 555: ...d Maintenance i e this chapter See also the maintenance cards Measuring the wall thickness The following special tools are required Wall thickness measuring device material no 454460 Note Observe all...

Страница 556: ...minimum required see table Type Minimum mm No DN 125 up to 85 bar P1 P2 Twin Pipe Twin Cast 1 1 Delivery line elbow 7 1 3 6 4 1 3 6 1 2 Delivery line elbow 7 0 2 0 7 0 3 0 2 1 2 5 2 0 2 5 3 3 2 2 Deli...

Страница 557: ...find the most important key words with the number of the page on which you will find the key word as a heading in the left margin This Index of key words is listed alphabetically by the main concepts...

Страница 558: ...Index of key words 6 II...

Страница 559: ...TOP function Checking the safety function 3 5 Description of the functions 3 5 Function check 3 6 Exhaust fumes 2 11 F Faults Recovering the machine 4 5 Filter change Pressure filter 5 53 Suction filt...

Страница 560: ...ety functions 3 1 Plates 3 16 Safety related parts SRPs 3 2 Separating protective devices 3 12 Safety functions Active 3 1 Agitator safety cutout 3 7 EMERGENCY STOP function 3 5 Grille 3 14 Passive 3...

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