Manual safety regulation_EN

Operating Instructions

for machine operator and maintenance staff
always keep by the machine

Translation of the original Operating Instructions BSF 42–5.16 H

Truck–mounted
concrete pump

Machine no. 210109187

15−11−18 E Putzmeister Concrete Pumps GmbH 1994

The paper on which this document is printed is 100% chlorine free

Putzmeister Worldwide

DeutschĆ Putzmeister Concrete Pumps GmbH +49−7127−599−0 [email protected]
land Max−Eyth−Strasse 10
PM D− 72631 Aichtal +49−7127−599−520 www.putzmeister.de

España Putzmeister Ibérica S.A. +34−91−428 81 00 [email protected]
PME Camino de Hormigueras 173 +34−91−428 81 43 www.putzmeister.es
Pol. Ind. Vallecas
France E− 28031 Madrid +33−164 64 39 39 [email protected]
PMF +33−164 64 39 29 www.putzmeister.fr
Putzmeister France
Italia 3, rue Paul Henri Spaak +39−541−85 15 11 [email protected]
PMI ZAE Jean Monnet +39−541−98 98 59 www.putzmeister.it
77240 Vert Saint Denis

Putzmeister Italia S.r.l.
Via Marconi, 2
I− 47832 San Clemente (RN)

Great Putzmeister Limited +44−1246−2642 00 [email protected]
Britain Carrwood Road +44−1246−26 00 77 www.putzmeister.co.uk
PMUK GB−Chesterfield +90−282−735−1000 [email protected]
Derbyshire S41 9QB +90−282−738−1001 www.putzmeister.com.tr
Türkiye +1−262−886−3200 [email protected]
PTR Putzmeister Makine Sanayi ve Tic. A.ƞ +1−262−886−3212 www.putzmeister.com
G.O.PaƟa Mah.
USA Naműk Kemal Bulvarű No: 6
PMA 59500 Çerkezköy / TEKŰRDAŞ

Putzmeister America
1733 90th Street
Sturtevant, WI 53177 USA

South Putzmeister S.A. (Pty) Ltd. +27−11−794−37 90 [email protected]
Africa Cnr. Bramm & Citrus St. Honeydew +27−11−794−41 19 www.putzmeister.co.za
PMSA P.O.Box 5146 ZA 2118 Cresta +91ć832ć6696000 [email protected]
South Africa +91ć832−6696300 www.pmw.co.in
India +81−47−553−4140 pmjapan@pm−j.co.jp
PCM Putzmeister Concrete Machines Pvt Ltd +81−47−553−4145 www.putzmeister.de/pmj
Plot No. N4, Phase IV +82−31−433−4541 [email protected]
Japan Verna Industrial Estate, Verna Salcete +82−31−498−7230 www.putzmeister.co.Kr
PMJ Goa−403722 +86−21−5774 1000 pmshangh@puĆ
+86−21−5774 2779 blic.sta.net.cn
Korea Putzmeister Japan Ltd. +7−495−775−22−37 www.putzmeister.com.cn
PMK Chiba East Techno Green Park (CETEC) +7−495−775−22−34 [email protected]
1−3 Okayamadai, Togane City, www.putzmeister.ru
P.R.China Chiba 283 0826, Japan
PMS
Putzmeister Korea Co. Ltd.
Russland 1287−1, Chungwang−Dong
PMR Shihwa Ind. complex 2 MA 707−1 HO
Shihung−city Kyonggi−Do, Korea

Putzmeister Machinery Shanghai Co. Ltd
39 Dongjing Road
Songjiang Industrial Zone
201613 Shanghai, P.R.China

OOO ĘPutzmeister−Rus
Urgumskaja Straße 4, Geb. 31
129343 Moskau, Russia

de Übersetzung der Originalbetriebsanleitung
bg Ïðåâîä íà îðèãèíàëíî Ðúêîâîäñòâî çà ðàáîòà
cs Pƙeklad originálního návodu k obsluze
da Oversættelse af den originale driftsvejledning
el MetÜfrash tou prwtotýpou twn odhgiþn leitourgßaj
en Translation of the original Operating Instructions
es Traducción de las instrucciones de servicio originales
et Algupärase kasutusjuhendi tõlge
fi Alkuperäisen käyttöohjeen käännös
fr Traduction des instructions de service originales
hr Prijevod izvornika naputka za uporabu
hu Eredeti üzemeltetési útmutató fordítása
it Traduzione delle istruzioni d’uso originali
lt Eksploatavimo instrukcijos originalo vertimas
lv Lietoơanas pamŁcūbas tulkojums no oriţinŁlvalodas
nl Vertaling van de oorspronkelijke gebruiksaanwijzing
no Oversettelse av original brukerhåndbok
pl TƂumaczenie oryginalnej instrukcji eksploatacji
pt Tradução das Instruções de funcionamento originais
ro Traducerea instrucƣiunilor de funcƣionare originale
ru Gthtdjl abhvtzzjuj herjdjlcndf gj ärcgkefnfwbb
sk Preklad originálneho návodu na obsluhu
sl Prevod izvirnih navodil za uporabo
sv Översättning av original instruktionsbok
tr Orijinal kullanűm kűlavuzunun tercümesi

BP00_030_0911EN



Table of contents

Table of contents 1 Guide to the Operating Instructions

210109187 1.1 Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 — 1
1.2 Icons and symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 — 3

2 Safety regulations

2.1 Definition of terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 1
2.1.1 Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 1
2.1.2 Concrete pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 1
2.1.3 Boom pedestal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 1
2.1.4 Arm assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 1
2.1.5 Placing boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 1
2.1.6 Base structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 1
2.1.7 Truck mixer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 2
2.1.8 Delivery line systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 2
2.1.9 Guiding the end hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 2
2.1.10 Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 2
2.1.11 Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 2
2.1.12 Machine operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 2
2.1.13 Hoseman . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 2
2.1.14 Signaller and other auxiliary personnel . . . . . . . . . . . . . . . . . . 2 Ċ 2
2.1.15 Truck mixer driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 3
2.1.16 Authorized inspector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 3
2.1.17 Subject expert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 3
2.1.18 Qualified personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 3
2.1.19 After Sales Service personnel . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 3
2.1.20 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 3
2.1.21 Place of work, working area, danger zone . . . . . . . . . . . . . . . 2 Ċ 4

2.2 Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 9
2.2.1 Retesting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 9
2.2.2 Inspection intervals for retesting . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 10

2.3 Use contrary to designated use . . . . . . . . . . . . . . . . . . . . . . 2 — 11
2.3.1 Transporting goods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 11
2.3.2 Lifting loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 11
2.3.3 Removing obstacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 11

I

Table of contents

2.3.4 Extending the reach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 11
2.3.5 Extending the placing boom and end hose . . . . . . . . . . . . . . 2 Ċ 12
2.3.6 Impermissible end hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 12
2.3.7 Impermissible working area . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 13
2.3.8 Climbing the placing boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 13
2.3.9 High−pressure delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 14
2.3.10 Accessories and attachments . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 14

2.4 Exclusion of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 14

2.5 Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 15
2.5.1 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 15
2.5.2 Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 15
2.5.3 Responsibility of the machine operator . . . . . . . . . . . . . . . . . . 2 Ċ 15

2.6 Operating Instructions, operating procedures and
other regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 16
2.6.1 Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 16
2.6.2
2.6.3 Operating procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 17

Other regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 17

2.7 Personal protective equipment . . . . . . . . . . . . . . . . . . . . . . . 2 — 18

2.8 Before starting work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 20
2.8.1 Checking that the machine is ready for operation . . . . . . . . 2 Ċ 20
2.8.2 Rendering the machine ready for operation . . . . . . . . . . . . . 2 Ċ 20

2.9 Danger due to high–voltage . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 21
2.9.1 High−voltage lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 21
2.9.2 Discharge voltage pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 21
2.9.3 Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 21
2.9.4 High−voltage warning devices . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 23
2.9.5 Procedure in the event of a flash over . . . . . . . . . . . . . . . . . . . 2 Ċ 23
2.9.6 Earthing in the event of electrostatic charging . . . . . . . . . . . 2 Ċ 24

2.10 Stationary machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 25
2.10.1 SetĆup site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 25
2.10.2 Stationary booms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 25
2.10.3 Lifting machines and components . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 26
2.10.4 Loading and transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 26

2.11 Mobile machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 27
2.11.1 SetĆup site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 27

II 210109187

Table of contents

2.11.2 Supporting ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 28
2.11.3 Corner bearing loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 29
2.11.4 Supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 30
2.11.5 Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 32
2.11.6 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 33
2.11.7 Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 34

2.12 Placing booms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 35
2.12.1 Unfolding the placing boom . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 35
2.12.2 Guiding the end hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 37
2.12.3 Guiding the end hose ergonomically . . . . . . . . . . . . . . . . . . . 2 Ċ 38
2.12.4 Procedure in storms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 39
2.12.5 Concreting in cold weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 39

2.13 Delivery line systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 40
2.13.1 Suitable delivery lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 40
2.13.2 Securing delivery lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 40
2.13.3 Tightness and blockages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 41
2.13.4 Opening delivery lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 42
2.13.5 Clearance to delivery lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 42
2.13.6 Fastening delivery lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 42
2.13.7 Continuation delivery lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 43
2.13.8 Devices for shutting−off, diverting or cleaning delivery lines 2 Ċ 43

2.14 Pumping operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 44
2.14.1 Place of work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 44
2.14.2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 44
2.14.3 Remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 44
2.14.4 Moving machine components and hot surfaces . . . . . . . . . . 2 Ċ 45
2.14.5 Constant observation of the machine . . . . . . . . . . . . . . . . . . . 2 Ċ 45
2.14.6 Truck mixer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 45

2.15 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 46
2.15.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 46
2.15.2 Cleaning agents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 47
2.15.3 Cleaning with compressed air . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 48
2.15.4 Protection against water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 49
2.15.5 Post−cleaning procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 49

210109187 III

Table of contents

3 General technical description

3.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 1

3.2 Safety equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 3

3.3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 6
3.3.1 Electromagnetic compatibility (EMC) . . . . . . . . . . . . . . . . . . . 3 Ċ 6
3.3.2 Machine rating plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ċ 8
3.3.3 Boom rating plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ċ 9
3.3.4 Sound pressure level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ċ 11
3.3.5 Sound power level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ċ 11
3.3.6 Reaches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ċ 13

3.4 Description of the functions . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 14
3.4.1 Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ċ 14
3.4.2 Delivery line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ċ 14
3.4.3 Support legs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ċ 14
3.4.4 Hydraulic control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ċ 14
3.4.5 Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ċ 15
3.4.6 S transfer tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ċ 15

3.5 General conditions for using a concrete pump . . . . . . . . 3 — 16
3.5.1 Service life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ċ 16
3.5.2 Site of use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ċ 17
3.5.3 Height of job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ċ 17
3.5.4 Operating temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ċ 18

IV 210109187

Table of contents

3.6 Electrical control devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 19
3.6.1 Central modular control cabinet . . . . . . . . . . . . . . . . . . . . . . . . 3 Ċ 20
3.6.2 OSS equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ċ 22
3.6.3 Ergonic Graphic Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ċ 23
3.6.4 Ergonic Output Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ċ 64
3.6.5 Control panel in the steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ċ 68
3.6.6 Cable remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ċ 70
3.6.7 Radio remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ċ 72
3.6.8 Ergonic Graphic Display − Remote Control . . . . . . . . . . . . . . 3 Ċ 77
3.6.9 Radio remote control battery charger . . . . . . . . . . . . . . . . . . . 3 Ċ113
3.6.10 Spotlights for lighting the support area . . . . . . . . . . . . . . . . . . 3 Ċ115
3.6.11 EMERGENCY STOP button . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ċ116
3.6.12 Magnetic switches distributor casing . . . . . . . . . . . . . . . . . . . 3 Ċ119
3.6.13 Magnetic switch connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ċ121
3.6.14 Agitator safety cutout (RSA) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ċ123

3.7 Hydraulic control devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 —125
3.7.1 Support control block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ċ126
3.7.2 Boom control block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ċ130
3.7.3 Pump control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ċ131
3.7.4 Centralized gauge ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ċ132

3.8 Other components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 —133
3.8.1 End hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ċ134
3.8.2 Flushing water pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ċ145
3.8.3 Water box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ċ146
3.8.4 Vibrator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ċ148
3.8.5 Hydraulic fluid radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ċ149
3.8.6 Truck engine manual throttle lever . . . . . . . . . . . . . . . . . . . . . . 3 Ċ152

210109187 V

Table of contents

4 Driving, towing and loading

4.1 Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 — 1
4.1.1 Hand signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Ċ 1
4.1.2 Before moving off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Ċ 2
4.1.3 During the journey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Ċ 3

4.2 Hand signals for driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 — 4
4.3 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 — 6

4.4 Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 — 10

5 Operation

5.1 Starting up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 — 1
5.1.1 Test run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ 1
5.1.2 Functional fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ 2
5.1.3 Engaging the transfer gearbox power take−off . . . . . . . . . . . 5 Ċ 3
5.1.4 Remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ 8
5.1.5 Acknowledge the agitator safety cutout . . . . . . . . . . . . . . . . . 5 Ċ 22

5.2 Centralized lubrication system . . . . . . . . . . . . . . . . . . . . . . . 5 — 23
5.2.1 Centralized lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ 24
5.2.2 Filling the lubricant reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ 24
5.2.3 Additional lubrication procedure . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ 26

5.3 Set–up site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 — 27
5.3.1 Space requirement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ 28
5.3.2 Danger zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ 30
5.3.3 Lightning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ 30
5.3.4 Minimum clearance from pits . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ 31
5.3.5 Safe clearance from pits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ 32
5.3.6 Supporting ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ 32
5.3.7 Support area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ 34

VI 210109187

Table of contents

5.4 Supporting the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 — 40
5.4.1 Working area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ 41
5.4.2 Remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ 42
5.4.3 ergonic 2.0 remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ 43
5.4.4 Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ 44
5.4.5 Danger zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ 46
5.4.6 Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ 47
5.4.7 Spirit level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ 48
5.4.8 Forward support legs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ 49
5.4.9 Rear support legs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ 50
5.4.10 Forward support feet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ 51
5.4.11 Rear support feet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ 52
5.4.12 Switching off the support function . . . . . . . . . . . . . . . . . . . . . . 5 Ċ 53

5.5 Special case “One-Side-Support” . . . . . . . . . . . . . . . . . . . . 5 — 54
5.5.1 Supporting the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ 55
5.5.2 Restricted working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ 59
5.5.3 Switching off the support function . . . . . . . . . . . . . . . . . . . . . . 5 Ċ 60

5.6 Function checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 — 61
5.6.1 Pump functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ 61
5.6.2 Filter functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ 63
5.6.3 EMERGENCY STOP function . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ 65
5.6.4 Function check on the boom control block . . . . . . . . . . . . . . 5 Ċ 67
5.6.5 Function check of the agitator safety cutout . . . . . . . . . . . . . 5 Ċ 68

5.7 Boom movements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 — 70
5.7.1 Restrictions on use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ 71
5.7.2 Danger zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ 72
5.7.3 Spontaneous retraction of the boom cylinders
and support cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ 76
5.7.4 Uncontrolled boom movements . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ 78

5.8 Hand signals for boom and pumping operations . . . . . . 5 — 80

210109187 VII

Table of contents

5.9 Unfolding the 5 RZ boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 — 87
5.9.1 Unfolding sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ 89
5.9.2 Impermissible working range . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ 95

5.10 Unfolding the boom when using One–Side–Support . . . 5 — 96

5.11 Filling and draining the water box . . . . . . . . . . . . . . . . . . . . 5 —102

5.12 Pumping operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 —105
5.12.1 Dangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ105
5.12.2 Notes on correct pumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ109
5.12.3 Starting pumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ112
5.12.4 Pumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ113
5.12.5 Possible faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ115
5.12.6 Special cases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ119

5.13 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 —121
5.13.1 Delivery line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ129
5.13.2 Hopper, delivery cylinder and SĂtransfer tube . . . . . . . . . . . . 5 Ċ135
5.13.3 Truck superstructure and postĆwashing operations . . . . . . . 5 Ċ144

5.14 Driving position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 —146
5.14.1 Folding sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ147
5.14.2 Retracting the supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ151
5.14.3 Remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ152
5.14.4 Disengaging the transfer gearbox power take−off . . . . . . . . 5 Ċ154

5.15 Driving position when using One–Side–Support . . . . . . . 5 —158
5.15.1 Retracting the supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ163
5.15.2 Remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ164
5.15.3 Disengaging the transfer gearbox power take−off . . . . . . . . 5 Ċ166

5.16 Measures for preserving the value of concrete pumps
and placing booms in storage . . . . . . . . . . . . . . . . . . . . . . . . 5 —170

VIII 210109187

Table of contents

Index of key words

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 technical terms . . . . . . . . . . . . . . . . . . . G — 15

210109187 IX



1 Guide to the Operating Instructions

In this chapter you will find notes and information that will help you
use these Operating Instructions. Do not hesitate to contact us if you
have any queries:
Putzmeister Condrete Pumps GmbH
After Sales Department
Max−Eyth−Straße 10
D−72631 Aichtal
Germany
Telephone +49 7127 599−0
Telefax +49 7127 599−520
e−mail: [email protected]
or the Branch or Works Agency that looks after you.

Address:

Telephone:
Telefax:
e−mail:

BP01_001_0802EN



1.1 Foreword Guide to the Operating Instructions

These Operating Instructions are intended to familiarize the user with
the machine and to assist him in using the machine properly in variĆ
ous operations.

The Operating Instructions contain important information on how to
operate the machine safely, properly and efficiently. Observing these
instructions helps to avoid danger, to reduce repair costs and downĆ
times, and to increase the reliability and service life of the machine.

The Operating Instructions are to be supplemented by the respective
national rules and regulations for accident prevention and environĆ
mental protection.

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

These Operating Instructions must be read and applied by any perĆ
son in charge of carrying out work with and on the machine e.g.
− operation, including setting up, troubleshooting in the course of

work, evacuation of production waste, care and disposal of fuels
and consumables;
− service (maintenance, inspection, repair), and/or
− transport.

In addition to the Operating Instructions and mandatory rules and
regulations for accident prevention in the country and place of use of
the machine/plant, the generally−recognized rules of technology for
safe and proper working must also be observed.

BP01_002_0802EN 1ĂĊĂ1

Guide to the Operating Instructions

Should you have any questions following your study of the Operating
Instructions, the Branch or Agency serving you, or the Aichtal Works
will be happy to give you more information.

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

These Operating Instructions describe the vehicle superstructure
only. The Operating Instructions issued by the vehicle manufacturer
apply for the vehicle itself.

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

In the event of any amendment, the copy of the Operating InstrucĆ
tions intended for the machine will be replaced in full.

The reproduction, distribution and utilization of this document as well
as the communication of its contents to others without explicit authorĆ
ization is prohibited. Offenders will be held liable for the payment of
damages. All rights reserved in the event of the grant of a patent,
utility model or design.

© Putzmeister Condrete Pumps GmbH 1994

1ĂĊĂ2 BP01_002_0802EN

Guide to the Operating Instructions

1.2 Icons and symbols The following icons and symbols are used in the Operating
" Instructions:
å
Task symbol
Text following this symbol describes tasks which you are required to
work through from top to bottom in the sequence shown.

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

See also the maintenance cards:
This icon is used to refer to the maintenance cards required,
possibly as a supplement to the maintenance card you are currently
reading.

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

Environmental protection
Particular specifications regarding environmental protection are
introduced by the icon shown, the words Environmental protection"
printed in bold, and a line. The associated text is printed in italics
and ends with another line.

Note
Particular information regarding the economic use of the machine is
introduced by the icon shown, the word Note" printed in bold, and
a line. The associated text is printed in italics and ends with another
line.

Caution
Particular information or rules or prohibitions intended to prevent
damage are introduced by the icon shown, the word Caution"
printed in bold, and a line. The associated text is printed in italics
and ends with another line.

BP01_003_0601EN 1ĂĊĂ3

Guide to the Operating Instructions

Danger
Particular information or rules or prohibitions intended to prevent
personal injury or significant damage are introduced by the icon
shown, the word Danger" printed in bold, and a line. The associated
text is printed in italics and ends with another line.

The appropriate icon will be used if it is 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 identify actions during which there is the danger
of an explosion. The explosion may also be caused by pressure
being released suddenly.

Falling itemsā
This icon is used to identify actions in which there is a risk of injury
caused by parts falling down.

Danger of crushing
This icon is used to identify actions during which there is the danger
of being crushed.

1ĂĊĂ4 BP01_003_0601EN

Guide to the Operating Instructions

Suspended load
This icon is used to identify actions in which suspended loads may
fall down.

High voltage
This icon is used to identify actions in which there is the danger of
electrocution, possibly 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
This icon is used to identify actions in which there is a danger of
burning from battery acid.

Danger of poisoning
This icon is used to identify actions in which there is a danger of
poisoning by inhalation of gases, ingestion of or contact with
substances.

BP01_003_0601EN 1ĂĊĂ5



2 Safety regulations

These safety regulations conform to the chapters Terms, definitions,
requirements" and Setting 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 regulaĆ
tions. This chapter is particularly suitable as an initial basic instrucĆ
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:
ć EN 12001, Conveying, spraying and placing machines for conĆ

crete and mortar
ć EN 12100, Safety of machinery,
ć EN 60204Ć1, Electrical equipment of machines.
ć in the Federal Republic of Germany: BGR 182, Concrete pumps

and placing booms.

BP03_081_1101EN



Safety regulations

2.1 Definition of terms The terms used in this Safety Manual are explained below, along with
2.1.1 Machine descriptions of the requirements placed on specific groups of
people.
2.1.2 Concrete pump
2.1.3 Boom pedestal In this Safety Manual, concrete delivery and placing machines refer
2.1.4 Arm assembly to:
2.1.5 Placing boom − Truck−mounted concrete pumps (ensemble of truck, concrete
2.1.6 Base structure
pump with and without placing boom). The truck manufacturer’s
Safety Manual also apply to the truck.
− Truck mixer concrete pump (an ensemble of truck mixer, concrete
pump and placing boom). The Safety Manual issued by the truck
mixer manufacturer and by the truck manufacturer also apply 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 defined
as devices which are designed to deliver concrete to placement
sites via pipes or hoses.

In this Safety Manual, boom pedestal refers to a device for holding
and guiding an arm assembly.

For the purposes of this Safety Manual, arm assemblies are powered
slewable devices consisting of one or more swinging or folding secĆ
tions for guiding the delivery line.

In this Safety Manual, placing boom refers to a unit comprising the
arm assembly and boom pedestal.

For the purposes of this Safety Manual, base structures are defined
as equipment which is designed to hold a stationary placing boom to
give the latter the required stability.

BP03_082_1501EN 2ĂĊĂ1

Safety regulations

2.1.7 Truck mixer In this Safety Manual, truck mixers are vehicles with mixing equipĆ
ment for transporting concrete.

2.1.8 Delivery line systems For the purposes of this Safety Manual, delivery line systems are deĆ
fined as self−contained pipes or hoses in which concrete is pumped
from the concrete pump to the placement site. Devices for shutting−
off, diverting or cleaning delivery lines can be integrated into delivery
line systems.

2.1.9 Guiding the end hose The "end hose" as referred to in this Safety Manual is the hose that is
fitted on the arm assembly at the end of the delivery line for distributĆ
ing the concrete. There must be no couplings, spouts, discharge
stops or other items fixed to the outlet end of the end hose unless
they are approved by the manufacturer.

2.1.10 Manufacturer Any natural or legal person that markets a machine or incomplete
machine that is dealt with in this Safety Manual

2.1.11 Operator Authorized representative of the owner of the concrete pumps and/or
placing booms. The operator is responsible for the use of these maĆ
chines.

2.1.12 Machine operator Person trained in and charged with the operation of concrete pumps
and placing booms.

2.1.13 Hoseman Persons instructed by the site management in how an end hose is
guided. Hosemen must be able independently to evaluate dangerĆ
ous situations which may occur in the area of the end hose and react
according to the situation.

2.1.14 Signaller and other Persons instructed by the site management to help the machine opĆ
auxiliary personnel erator in his work if the latter is unable to observe all areas of operĆ
ation and danger zones. Signallers must be able to independently
evaluate all dangerous situations which may occur when working
with a concrete pump and/or placing boom, and to react according
to the situation. The signaller must have a suitable means of comĆ
munication with the machine operator.

2ĂĊĂ2 BP03_082_1501EN

Safety regulations

2.1.15 Truck mixer driver Person who supplies the concrete pump with concrete from a truck
mixer. Truck mixer drivers must be instructed by the machine operĆ
ator to operate the operating elements on the concrete pump proĆ
vided for their use. Truck mixer drivers must be able to indepenĆ
dently evaluate all dangerous situations which may occur when
working in the area of the hopper of a concrete pump, and to react
according to the situation.

2.1.16 Authorized inspector Authorized inspectors are persons empowered by the relevant govĆ
ernment bodies to carry out this task of inspection. The prerequisites
for becoming an authorized inspector are:
− To have completed a higher education course in engineering or

similar.
− To have at least 5 years’ professional experience in a relevant doĆ

main, of which at least six months must have involved participation
in the work of an authorized inspector.
− To possess thorough knowledge of the relevant health and Safety
Manual, as well as of directives and the generally recognised rules
of engineering.
− To have access to the necessary equipment to carry out the inĆ
spection.
− To be able to carry out the tasks impartially.

2.1.17 Subject expert For the purposes of this Safety Manual, a subject expert is a person
who, through their professional training, their professional experience
and their recent professional activity, has the required specialist
knowledge to inspect the tools.

2.1.18 Qualified personnel Persons who have completed specialist training for a particular activĆ
ity which qualifies them to carry out their roles.

2.1.19 After Sales Service Qualified persons employed by the manufacturer who are responĆ
personnel sible in particular for maintenance of the machine.

2.1.20 Maintenance Maintenance embraces all measures required for inspection, servicĆ
ing and repair of a machine.

BP03_082_1501EN 2ĂĊĂ3

Safety regulations

2.1.21 Place of work, working area, danger zone

Mobile machines

14 26 7
16
8 ab0005
3
9 5 11
10 10
11 9
12 8
2
Stationary machines Example
ab0010
14 3
4
4 1
13
3 66 13
5
13 12
1
11

Example

2ĂĊĂ4 BP03_082_1501EN

Safety regulations

No. 0 Designation Explanation
1
2 Place of work Machine operator In normal operation, with the remote control
3 (during pumpĆ Hoseman At the end hose in the danger zone
4 ing operĆ Signaller In the machine operator’s range of vision
5 ations) Auxiliary personnel As manual placing system operators
6 Truck mixer driver At the hopper in the danger zone
7 Area with a radius of the reach of the placing boom
Working area Permitted + end hose length
8 Impermissible The end hose must not be moved backwards beĆ
yond the vertical of the placing boom
9 At the end hose Risk of injury when pumping is started, during
pumping operations, when removing a blockage
10 Danger zone Beneath the placing and during washing out procedures. The diameter
boom of the danger zone is twice the end hose length.
11 Area of the support
12 legs and feet Risk of injury from falling items
13 or area of the base
14 structure Danger of crushing when the machine is set up and
when the supports are retracted
On the machine
Any presence on or below the machine when the
at the hopper pump is in operation is prohibited
Risk of injury during washing out procedures and
Area of the delivery when the hopper is being filled using a truck mixer
line systems Hazard posed if lines burst, risk of injury from crushĆ
Structure or area being concreted ing or shearing, particularly with gate valves
Example

BP03_082_1501EN 2ĂĊĂ5

Safety regulations

Place of work The place of work is the area in which people must remain in order to
carry out the work.

Place of work − maĆ The machine operator’s place of work is with the remote control when
chine operator the pump is in operation. The place of work must be selected so as
to allow visual contact with the site of concrete placement, and the
truck mixer driver, and so that the working area can be observed at
the same time. A signaller must otherwise be used.

The operator’s place of work is with the machine when this is being
set up or prepared for driving.

Place of work − hoseĆ The hoseman’s place of work is within the danger zone of the end
man hose, but not beneath the placing boom. This requires a greater level
of caution. The hoseman and machine operator must have visual
contact.

Place of work − truck The truck mixer driver’s place of work is in the danger zone of the
mixer driver hopper and at operating elements for the agitator and truck mixer.
This requires a greater level of caution. The truck mixer driver and
Working area machine operator must have visual contact.

The working area is the area in which work is carried out with or on
the machine. Parts of the working area can become danger zones
depending on the operation being carried out and the position of the
placing boom.

The working area must be secured and clearly identified. Suitable
personal protective equipment is required in the working area. The
machine operator is responsible for safety in the working area of the
machine whilst the machine is in use.

Impermissible working Because of their high manoeuvrability, some placing booms can also
area be shifted into positions for which they are not designed. This may
overload or damage the placing boom. Placing booms must thereĆ
fore only be moved within the permitted working area.

2ĂĊĂ6 BP03_082_1501EN

Safety regulations

Danger zone The danger zone is the area surrounding the machine, in which
people may be at risk of injury from movements required by the
work.

The danger zone varies within the working area, and depends on the
activity being carried out and the position of the placing boom, if one
is present. Danger zones must be secured and clearly identified. The
machine operator must be capable of seeing the danger zone at all
times and under all circumstances. If necessary he must appoint a
signaller to supervise the danger zone.

Depending on the working situation, workplaces may occasionally
fall within the danger zone, especially the workplace of the hoseman
and the truck mixer driver. If a workplace falls within the danger
zone, increased caution is required and suitable personal protective
equipment is prescribed. Persons who are authorized to be present
in such a workplace, must use their own discretion to assess the
hazards of the situation and be able to react accordingly.

The machine operator is responsible for safety in the danger zone of
the machine whilst the machine is in use.

The machine operator must stop work immediately and press the
EMERGENCY STOP button if an unauthorized person enters the
danger zone.

Support legs and supĆ There is a danger of crushing in the swingĆout and extension zone

port feet for the supports.

Placing boom The danger zone when working with the placing boom is the zone
over which the placing boom is slewed. In this area there is a risk of
injury from falling concrete and delivery line components.

BP03_082_1501EN 2ĂĊĂ7

Safety regulations

Machine All the time the vehicle is in operation, there is a risk of injury on and
below the machine from moving parts and bursting delivery lines or
hydraulic hoses, as well as a risk of falling on slippery surfaces or
steps.

Guiding the end hose The danger zone when pumping is started, during pumping operĆ
ations, when removing a blockage and during washing out proĆ
cedures is the area around the end hose in which the hose may
swing out. The diameter of the danger zone is twice the end hose
length.

Hopper In the area of the hopper, there is a risk of becoming trapped beĆ
tween the truck mixer and the hopper and of being sprayed with
concrete. There is a risk of being crushed and of injury by shearing
from the transfer tube. There is a risk of being entrapped by the roĆ
tating agitator.

Delivery line systems In the area around the delivery line systems there is a risk of injury
from the delivery line bursting if there is an abrupt rise in pressure.
There is a risk of crushing and injury by shearing with devices inteĆ
grated in delivery line systems.

2ĂĊĂ8 BP03_082_1501EN

Safety regulations

2.2 Designated use The machine must only be operated as intended and in technically
perfect condition. All protective and safetyĆoriented devices, particuĆ
larly removable protective devices and EMERGENCY STOP devices,
must be available and fully functional.

The machine is designed 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 concrete
pressure must not exceed that specified on the rating plate or in the
check book.

You must also observe the Safety Manualand comply with the interĆ
vals and conditions for inspections (particularly retesting) and mainĆ
tenance work in order to operate the machine within the limits of its
proper use.

2.2.1 Retesting After initial commissioning of the machine, the operational safety of
the machine must be checked regularly by a subject expert. The inĆ
spection intervals depend on the age of the machine. The older the
machine, the greater the probability of damage. This is why regular
retesting of the machine, appropriate to its age, is an effective
means for the early detection of damage.

Retesting must 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 effectiveness of the safety
equipment;
− retesting to find out whether any defects which are found during
the tests mentioned above and which could affect safety have
been adequately rectified.

Furthermore, information provided by the manufacturer to the operĆ
ator with reference to special instructions for maintenance and inĆ
spection must be observed.

BP03_082_1501EN 2ĂĊĂ9

Safety regulations

2.2.2 Inspection intervals The inspection intervals are fixed as follows:
for retesting
Machines of up to and including 5Ăyears old:
Inspect after every 1,000 operating hours or 1 year, whichever is
soonest. The interval is repeated after every retest.

Machines more than 5Ăyears old:
Inspect after every 500 operating hours or 1 year, whichever is
soonest. The interval is repeated after every retest.

Machines more than 10Ăyears old:
Inspect after every 250 operating hours or 1 year, whichever is
soonest. The interval is repeated after every retest.

The day of initial commissioning in accordance with the handover
report and the machine’s operating hours meter are definitive for the
intervals. This operating hours 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 machines without an
operating hours meter, the operating hours must be comprehensibly
recorded in writing.

Retesting must be arranged by the operator. The results of retesting
must be entered in the check book and signed. The check book
must always be kept with the machine and must be produced upon
the request of the national supervisory bodies.

Notwithstanding national legislation, the operator can be liable in the
event of damage, if it is proved that the damage has arisen as a
consequence of regular retesting not being properly carried out.

If retesting is not carried out, the manufacturer will assume that the
machine has been shut down. When the machine is restarted, retestĆ
ing must be carried out.

2ĂĊĂ10 BP03_082_1501EN

Safety regulations

2.3 Use contrary to desig- Any use of the machine which is not described in section 2.2, enĆ

nated use titled Designated use", or which extends beyond the uses deĆ

scribed in this section is deemed to be contrary to designated use.

The manufacturer accepts no liability for damage resulting from such

use. Some examples of conceivable uses that are contrary to the

designated use are given below.

2.3.1 Transporting goods The machine may not be used for the transport of goods, except for
carrying the accessories used for the machine, such as pipes,
hoses, etc. The maximum permissible gross weight may not be exĆ
ceeded.

2.3.2 Lifting loads The placing boom must never be used for lifting loads.

wz0006

2.3.3 Removing obstacles The placing boom must not be used under any circumstances to reĆ
2.3.4 Extending the reach move obstacles. This would overload the placing boom, causing
damage and endangering people.

It is prohibited to attach an extension (e.g. freely suspended crossĆ
beam) to the end hose or placing boom tip in order to extend the
reach or to pump at an angle. Since the boom and the lifting equipĆ
ment for the extension have differing pivot points and modes of conĆ
trol, it is not possible to co−ordinate their movements.

BP03_082_1501EN 2ĂĊĂ11

Safety regulations

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

If the manufacturer defines the weight rather than the length of the
end hose, you can use a reducer pipe with a longer end 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 2ĂĊĂ37).

End hoses with a length of more than 4 m must not be guided by
hand.

2.3.6 Impermissible end wz0016
hose
There must be no couplings, spouts, discharge stops or other items
fixed to the outlet end of the end hose unless they are approved by
the manufacturer.

2ĂĊĂ12 wz0195

BP03_082_1501EN

Safety regulations

2.3.7 Impermissible The end hose must not be moved backwards beyond the vertical of
working area the placing boom.

wz0026

2.3.8 Climbing the placing It is prohibited to climb the placing boom, to stand on top of it or to
boom misuse it as a working platform or aid to climbing.

wz0037

BP03_082_1501EN 2ĂĊĂ13

Safety regulations

2.3.9 High–pressure It is prohibited to deliver concrete at high−pressure (concrete presĆ
delivery sure greater than 85 bar) through the delivery line of the placing
boom. Delivery line elements are marked with the maximum permissĆ
2.3.10 Accessories and ible delivery pressure. The delivery line and end hose are only suitĆ
attachments able for concrete pressures of up to 85 bar until the wear threshold is
reached. For the wear threshold, refer to the Safety Manualfor the
2.4 Exclusion of liability machine.

It is prohibited to fit accessories and attachments to the machine if
they have not been expressly approved for use on this machine by
the manufacturer.

Where the manufacturer’s delivery conditions are agreed, liability will
be as described in the provisions there. The manufacturer is not liĆ
able for damage in cases specified there.

Unless the responsibility of the manufacturer, the warranty will be inĆ
validated in the following situations in particular:
− use contrary to designated use
− incorrect operation, maintenance and repair
− use of spare parts or accessories other than original manufacĆ

turer’s spare parts and accessories or their equivalents
− conversions, alterations or modifications to the machine
− fitting of accessories and attachments not approved by the manuĆ

facturer
− adjustment of safety pressures, speeds of movement, power outĆ

puts, speeds of rotation and other settings to values other than
those set in the works

2ĂĊĂ14 BP03_082_1501EN

Safety regulations

2.5 Personnel The operator must ensure that only persons who are qualified or
2.5.1 Requirements have received the necessary instruction work on or with the machine.
You can ask the machine manufacturer for suitable training. He must
clearly define who is responsible for operation and maintenance of
the machine. He must also ensure that only persons commissioned
to work on the machine do so.

Persons operating or carrying out maintenance work on the machine
must meet the following requirements:
− They must be aged 18 years or over.
− They must be physically and mentally capable.
− They must be physiologically capable (rested and not under the

influence of alcohol, drugs or medication).
− They must have been instructed in the operation and maintenance

of the machine.
− They must have demonstrated their competence to the operator.
− They can be expected to reliably execute the tasks with which

they are charged.

2.5.2 Qualifications The operating personnel must not wear loose garments or jewellery,
including rings. Long hair which is not tied back must be covered by
a hair net. There is a risk of injury, in particular from being caught or
trapped by moving parts.

Do not allow persons who have not yet completed training or instrucĆ
tion, or persons taking a general training course, to operate the maĆ
chine unless under the constant supervision of an experienced perĆ
son.

2.5.3 Responsibility of the If you do not have qualified personnel, suitable workshop equipment
machine operator etc. available, you should commission the manufacturer’s After Sales
Department with the maintenance of your machine.

The operator must define the responsibility of the machine operator
(including in respect to national road traffic regulations) and emĆ
power him to reject instructions from third parties prejudicial to
safety. The machine operator must be able to reject the site of operĆ
ations if he has doubts regarding technical safety.

BP03_082_1501EN 2ĂĊĂ15

Safety regulations

2.6 Operating Instructions, operating procedures and other regulations

2.6.1 Operating Personnel that are authorised to work on the machine must have
Instructions read the Operating Instructions working with the machine, particularly
the section Safety Regulations and the Safety Manual. Reading the
instructions after work has begun is too late. This applies especially
to persons working only occasionally on the machine, e.g. during set-
ting up or maintenance.

The Operating Instructions and check book must always be kept to
hand at the site of use of the machine (in the tool compartment or
container provided for this purpose).

As the operator, you must always make sure that the Safety Manua-
lare available. Have personnel working on the machine confirm in
writing their knowledge, understanding and application of the Operat-
ing Instructions and Safety Regulations and Safety Manual. At regular
intervals of at least once a year, check that personnel are conscious
of safety and the hazards involved in their work and are taking ac-
count of the Operating Instructions.

Personnel entrusted with work on the machine must observe all
safety instructions and hazard warnings, and must be familiar with the
machine itself. You must practice all the operating procedures de-
scribed in the Safety Manual (extending the supports, operating the
placing boom, shifting the placing boom into the driving position, pre-
paring the vehicle for moving, etc.) under the supervision of a subject
expert until you are certain you can execute them safely. Ask ques-
tions if there is something you have not understood. Begin operating
the machine only once you are familiar with the layout and signifi-
cance of all the control and monitoring devices and the functioning of
the machine in general.

2ĂĊĂ16 BP03_082_1501EN

Safety regulations

2.6.2 Operating procedures The operator must produce operating procedures for his personnel
in accordance with national regulations. These operating procedures
must include instructions covering the duties involved in supervising
and notifying special organisational features, e.g. organization of
work, working procedures or the personnel entrusted with the work.
Furthermore, reference must be made to other generally valid legal
and otherwise 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 equipment or with national road traffic regulations. You
should familiarise yourself with the site of operations and with how to
use fire extinguishers. Observe the fireĆalarm and firefighting proĆ
cedures.

2.6.3 Other regulations The current regulations for concrete delivery and placing machines
as issued by:
− the legal authorities in your country
− national supervisory bodies
− the responsible commercial liability insurance company are bindĆ

ing on the operator of the machine.

BP03_082_1501EN 2ĂĊĂ17

Safety regulations

2.7 Personal protective In order to reduce risks to personnel, personal protective equipment
equipment must be used in so far as this is necessary or deemed to be so by
regulations. All personnel working on or with the machine must wear
safety helmets, protective gloves and safety footwear.

Personal protective equipment must, as a minimum, comply with the
requirements of the specified standards.

Safety helmet
A safety helmet protects your 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 against falling objects and against
penetration by projecting nails.
(EN ISO 20345; Safety footwear for professional use;
Category S3)

Hearing protectors
Hearing protectors protect you against the noise generated by the
machine when you are standing close to it.
(DIN EN 352–1; Hearing protectors – General requirements –
Part 1: Earmuffs
or
DIN EN 352–3; Hearing protectors – General requirements –
Part 3: Earmuffs on safety helmet)

2ĂĊĂ18 BP03_082_1501EN

Safety regulations

Protective gloves
Protective gloves protect your hands against aggressive or chemical
substances, as well as against mechanical effects (e.g. impact) and
cutting injuries.
(DIN EN 388; Protective gloves against mechanical risks;
Class 1111)

Protective goggles
Protective goggles protect your eyes against injuries from concrete
spatters or other particles.
(DIN EN 166; Personal eye-protection – Specifications)

Safety 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 361; Personal Protective Equipment Against Falls from a
Height – Full Body Harnesses;
Category III)

Face mask and respiratory protection
A face mask and respiratory protection protect you against particles
of building materials which could enter your body through your respi-
ratory passages (e.g. concrete admixtures).
(DIN EN 149; Respiratory protective devices – Filtering half masks
to protect against particles – Requirements, testing, marking;
Class FFP1)

BP03_082_1501EN 2ĂĊĂ19

Safety regulations

2.8 Before starting work

2.8.1 Checking that the As machine operator, it is your responsibility to check the machine
machine is ready for external damage and defects before any use of the machine. You
for operation must immediately report any changes (including changes in the
working characteristics) to the organization or person responsible. If
2.8.2 Rendering the necessary, shut the machine down and secure it against use.
machine ready
for operation As machine operator, you are responsible for rendering the machine
ready for operation. This also includes topping up the functional
fluids. Do not fill with fuel in enclosed spaces. Switch off the engine
and the heating. Wipe up spilt fuel immediately. Do not smoke or use
a naked flame when handling fuel.

Set all the control and monitoring devices to the zero position before
you change the mode of control (control block, control console or
remote control). Press the EMERGENCY STOP button. otherwise the
machine might execute unintended movements.

Never put the remote control down when the machine is in ready
mode. If this is unavoidable in exceptional cases, you must switch off
the remote control, disconnect it and lock it away.

Never leave the machine when the engine is running or when the enĆ
gine could be started by an unauthorized person. If you need to
leave the machine, proceed as follows:
− Switch off the remote control.
− Disconnect the remote control and lock it away.
− Switch off the ignition or the main switch.
− Lock the control cabinet.

2ĂĊĂ20 BP03_082_1501EN

Safety regulations

2.9 Danger due to high–voltage

2.9.1 High–voltage lines Whenever you touch a high−voltage line, there is a risk of death for
all persons either on the machine or in its vicinity or who are conĆ
nected to it (via the remote control, end hose, etc.). A spark can
jump across from a high−voltage line even if you just approach it and
this will energize the machine and the surrounding area.

2.9.2 Discharge voltage In the event of a flash over, what is known as a discharge voltage
pattern pattern" is formed in the vicinity of the machine. The voltage deĆ
creases from the inside to the outside in this discharge voltage patĆ
tern. If you step within this discharge voltage pattern, you will bridge
different potentials. This will cause a voltage corresponding to the
potential difference to flow through your body.

2.9.3 Clearances Maintain a minimum clearance from high−voltage lines in accordĆ
ance with the following table. The minimum clearance is measured in
the horizontal when the placing boom is fully extended.

Rated voltage [V] Minimum clearance [m]
up to 1 kV 1,0
1 kV to 110 kV 3,0
110 kV to 220 kV 4,0
220 kV to 380 kV 5,0
unknown rated voltage 5,0

The specified clearances are minimum requirements. You must obĆ
serve any greater clearances that may be specified in the country of
use.

BP03_082_1501EN 2ĂĊĂ21

Safety regulations

wz0116

When you set a minimum clearance, the possibility of the high−voltĆ
age lines and the placing boom swaying in the wind must also be
taken into consideration. You should further note that where air huĆ
midity is high, clearances greater than the minimum clearances
shown above are always necessary.
You must stand as close as possible to the unfolded placing boom if
you wish to estimate correctly the movements of the boom and,
above all, the clearance between the placing boom and obstacles or
high−voltage lines.
The same minimum clearances are necessary when driving under
overhead cables.
In the event that this minimum clearance cannot be maintained
under all possible working positions, the power station responsible
must be contacted and you must have the high−voltage line
switched off.
Should you have any doubts, it is better to forego the use of the placĆ
ing boom and to lay a separate delivery line, for instance.

2ĂĊĂ22 BP03_082_1501EN

Safety regulations

2.9.4 High–voltage warning According to the current rules of engineering, high−voltage warning
devices devices do not meet a safety standard which enables a safe underĆ
shooting of the required minimum clearances to high−voltage lines.
Previous experience has shown that high−voltage warning devices
cannot make all situations in working procedures safe. Flash overs
and fatal accidents can occur despite the use of a high−voltage
warning device. You must therefore always maintain the minimum
clearances mentioned above.

2.9.5 Procedure in the Should a flash over occur, despite all precautions, stay calm, do not
event of a flash over move (potential differential), touch nothing.

wz0126

If your machine comes into contact with heavy current lines:
− Warn those outside against approaching and touching the maĆ

chine.
− Have the power switched off.
− Only leave the machine once you are sure that the line you have

touched or damaged has been de−energized.

BP03_082_1501EN 2ĂĊĂ23

Safety regulations

Power stations are always equipped with automatic switch−on deĆ
vices. If a circuit breaker trips, the short−circuited cable will be
switched back on again after a brief interval. Brief intervals when the
voltage is absent give rise to a false sense of safety.

You should only move and rescue injured persons once a represenĆ
tative of the power station has notified you that the cable has been
switched off.

2.9.6 Earthing in the event A radio remote control system only protects the machine operator if
of electrostatic he is standing outside the discharge voltage pattern.
charging
Faults can be caused in the radio remote control system and danĆ
gerous electrical charging of the machine can occur when working
in the vicinity of transmitters (radio transmitter, etc.). Persons who
bridge the charged parts to the earth are heavily charged on conĆ
tact.

Machines in use in the vicinity of transmitters must be earthed. SeĆ
cure the earthing cable (at least 16 mm2) to a specially prepared,
bare metal point of the machine (in particular, not to a piston rod)
and to a conductive metal rod in the ground (minimum insertion
depth of 1.5 m). Thoroughly dampen the earth around the metal rod
to make it more conductive.

Even when the machine is earthed, the safe clearances to high−voltĆ
age lines (see also page 2ĂĊĂ21) must be maintained and the inĆ
structions regarding storms and bad weather (see also
page 2ĂĊĂ39) must be observed.

If you have any further questions about earthing the machine, please
contact the construction site management or the operating company
of the machine.

2ĂĊĂ24 BP03_082_1501EN

Safety regulations

2.10 Stationary machines Stationary machines are generally used on a construction site for a
2.10.1 Set-up site lengthy period. For this reason, site management should prepare the
setĆup site carefully. The site management must deliver the necessĆ
ary documents in good time in order to be able to prepare the
foundations, base plates or similar on time.

When selecting the setĆup site, remember that the machine must be
dismantled and transported away again at the end of its use on site.
The ambient conditions may change as construction work progĆ
resses.

2.10.2 Stationary booms Please also observe section 2.11.1, Mobile machines, setĆup site".

Stationary booms can be erected on tubular columns, lattice booms
or other base structures. The base/structural elements to which the
base structure is fixed must be able to withstand the forces and moĆ
ments transferred via the base structure, as specified in the manuĆ
facturer’s information. The base frame of the base structure must be
fastened in place so that it is level on the base/structural elements in
every direction. Check the documentation provided by the manufacĆ
turer in this regard and the corresponding notes in the operating inĆ
structions.

BP03_082_1501EN 2ĂĊĂ25

Safety regulations

2.10.3 Lifting machines and Machines which are transported to the setĆup site in individual parts
components or not under their own power must only be lifted with suitable lifting
equipment in accordance with the specifications in the Operating
Instructions. The lifting gear on the machine must be capable of acĆ
cepting the lifting gear and lifting the load. NoĆone should stand
under suspended loads. Before work is started, a subject expert
must check that the assembled machine is working properly.

2.10.4 Loading and trans- Only use suitable means to load and transport stationary machines.
porting Ensure that noĆone can be injured by the machine tipping over or
slipping.

If there are transport fixtures provided for the machine or its individĆ
ual components, only these should be used. The machine/compoĆ
nents must be properly secured during transport. The transport veĆ
hicle and machine must be marked to conform with the road traffic
regulations in the country concerned if they are to use the public
highway.

Please also observe section 2.11.5, Mobile machines, driving".

2ĂĊĂ26 BP03_082_1501EN