Manual safety regulation_EN

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 Service Instructions

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

2 Safety regulations

2.1 Basic principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 1
2.1.1 Exclusion of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 1
2.2 Requirements for special work . . . . . . . . . . . . . . . . . . . . . . . 2 — 2
2.3 Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Ċ 7
2.8.2 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 8
2.8.3 Power at the construction site . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 8

2.9 Hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 9
2.9.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 9
2.9.2 Replacing hydraulic hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Ċ 10

2.10 Noise emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 10
2.11 Exhaust fumes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 11
2.12 Functional fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 11
2.13 Disposal of the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 12

210109187 I

Table of contents

3 Safety equipment

3.1 Overview of the safety equipment . . . . . . . . . . . . . . . . . . . . 3 — 1
3.1.1 Active safety functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ċ 1
3.1.2 Passive safety function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ċ 1
3.1.3 Organizational measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ċ 1
3.1.4 SafetyĆrelated parts (SRPs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ċ 2
3.1.5 Safety components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ċ 4
3.1.6 Parts with increased maintenance requirements . . . . . . . . . 3 Ċ 4

3.2 EMERGENCY STOP function . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 5
3.2.1 Description of the functions . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ċ 5
3.2.2 Function check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ċ 6

3.3 Agitator safety cutout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 7
3.3.1 Description of the functions . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ċ 8
3.3.2 Function check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ċ 9
3.3.3 Acknowledging the agitator safety cutout . . . . . . . . . . . . . . . 3 Ċ 10

3.4 Support control block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 11
3.4.1 Description of the functions . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ċ 11
3.4.2 Function check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ċ 12

3.5 Remote control/boom control block joysticks . . . . . . . . . 3 — 13
3.5.1 Joystick function description . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ċ 13
3.5.2 Function description for boom control block . . . . . . . . . . . . . 3 Ċ 14
3.5.3 Function check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ċ 15

II 210109187

Table of contents

3.6 Protective devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 17
3.6.1 Description of the functions . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ċ 17
3.6.2 Function check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ċ 17

3.7 Grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 19
3.7.1 Description of the functions . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ċ 19
3.7.2 Function check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ċ 20

3.8 Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 21
3.8.1 Description of the functions . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ċ 21
3.8.2 Function check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ċ 21

4 Special modes of operation

4.1 Emergency operation – pump function . . . . . . . . . . . . . . . 4 — 1
4.2
4.3 Emergency operation of the agitator and water pumps . 4 — 3

4.3.1 Boom control block (emergency control
4.4 lever for boom functions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 — 5
4.4.1 Example illustration of a boom control block . . . . . . . . . . . . . 4 Ċ 7
4.4.2
Recovering the machine after faults occur . . . . . . . . . . . . 4 — 8
Recovery with onĆboard equipment . . . . . . . . . . . . . . . . . . . . . 4 Ċ 9
Recovery with an external hydraulic power pack . . . . . . . . . 4 Ċ 15

210109187 III

Table of contents

5 Maintenance

5.1 Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 — 1

5.2 Residual risks during maintenance, inspection
and repair work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 — 4
5.2.1 Personal protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ 4
5.2.2 Personnel requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ 4
5.2.3 Auxiliary devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ 4
5.2.4 Residual risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ 5

5.3 General tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 — 7
5.3.1 Set screws and nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ 7
5.3.2 Flared screwed joint, reassembly . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ 8
5.3.3 Profiled ring joint, reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ 8
5.3.4 WALFORMplus threaded union . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ 9
5.3.5 WALFORMplus threaded union, reassembly . . . . . . . . . . . . . 5 Ċ 10

5.4 Functional fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 — 12
5.4.1 Hydraulic fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ 12
5.4.2 Level of contaminant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ 14
5.4.3 Lubricant analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ 14
5.4.4 Storage of lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ 14

5.5 Lubricant recommendation . . . . . . . . . . . . . . . . . . . . . . . . . . 5 — 15
5.5.1 Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ 17
5.5.2 Greases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ 18
5.5.3 Hydraulic fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ 19

IV 210109187

Table of contents

Maintenance cards

00−001 Visual checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ 23
01−021 Transfer gearboxes G64SB and G64SC . . . . . . . . 5 Ċ 25
01−024 Slewing gear transmission . . . . . . . . . . . . . . . . . . . 5 Ċ 31
01−020 Inspecting, cleaning and, if required,
lubricating the cardan shaft . . . . . . . . . . . . . . . . . . 5 Ċ 35
03−001 Changing the hydraulic fluid . . . . . . . . . . . . . . . . . . 5 Ċ 41
03−002 Function checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ 47
03−026 Checking the accumulator . . . . . . . . . . . . . . . . . . . 5 Ċ 49
03−025 Drain off condensate water . . . . . . . . . . . . . . . . . . . 5 Ċ 57
04−002 Hydraulic hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ 61
04−014 Changing the ventilation filter element . . . . . . . . . 5 Ċ 65
04−018 Hydraulic fluid filter change . . . . . . . . . . . . . . . . . . 5 Ċ 69
06−047 Delivery piston replacement on the dual
piston end−of−travel positioning system . . . . . . . . 5 Ċ 79
07−001 Lubricating the S transfer tube . . . . . . . . . . . . . . . . 5 Ċ 89
07−068 Replacing the transfer tube bearing . . . . . . . . . . . 5 Ċ 91
07−070 Replacing the switching shaft bearing
(flanged bearing) . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ċ 99
07−071 Replace the spectacle wear plate . . . . . . . . . . . . . 5 Ċ115
07−072 Replacing the S transfer tube . . . . . . . . . . . . . . . . . 5 Ċ129
07−073 Replacing the S transfer tube wear sleeve . . . . . 5 Ċ137
07−074 Replacing the thrust ring and wear ring . . . . . . . . 5 Ċ145
07−075 Adjusting the S transfer tube . . . . . . . . . . . . . . . . . 5 Ċ151
10−007 Measuring the wall thickness
(Machines with S transfer tube) . . . . . . . . . . . . . . . 5 Ċ165
10−044 Measuring the wall thickness of two−layer pipes 5 Ċ171
20−069 Lubricating the placing boom (M 42 RZ) . . . . . . . 5 Ċ173
21−054 Lubricating the boom pedestal (TRDI 110) . . . . . 5 Ċ175
21−001 Checking connecting bolts on the slewing ring . 5 Ċ179
25−001 Replacing the delivery line . . . . . . . . . . . . . . . . . . . 5 Ċ181

Index of key words

210109187 V



1 Guide to the Service Instructions

This chapter contains notes and information that will help you to use
these Service Instructions. Do not hesitate to contact us if you have
any queries:
Putzmeister Concrete Pumps GmbH
After Sales department
MaxĆEythĆStr. 10
72631 Aichtal
Telephone: +49 (0) 7127 5990
Fax: +49 (0) 7127 599 520
EĆmail: [email protected]
or contact the branch or works agency that is responsible for you.
Address:

Telephone:
Fax:
EĆmail:

BP01_009_1011EN



1.1 Foreword Guide to the Service instructions

The Service Instructions contain important information about the
maintenance of the machine. Observing these instructions helps to
avoid danger, to reduce repair costs and downtimes, and to increase
the reliability and service life of the machine.

The Service Instructions must be supplemented by the relevant
national rules and regulations for accident prevention and environĆ
mental protection.

The Service Instructions must always be available wherever the maĆ
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 operation, including setting up, fault rectification in the course of

work, removal of production waste, care and disposal of fuels and
consumables;
− maintenance (servicing, inspection, repair) and/or
− Transport
.

In addition to the Service Instructions and mandatory rules and reĆ
gulations for accident prevention in the country and place of use of
the machine, the generally recognized rules of technology for safe
and proper working must be observed.

BP01_010_1011EN 1ĂĊĂ1

Guide to the Service instructions

Should you have any questions after studying the Service InstrucĆ
tions, the branch or agency serving you, or the Aichtal Works, will be
happy to provide you with 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 Service 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 may be the case that we were unable to take
these into consideration when these Service Instructions were
printed.

In the event of any amendment, the copy of the Service Instructions
that is 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 Concrete Pumps GmbH 1994

1ĂĊĂ2 BP01_010_1011EN

Guide to the Service 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 Service 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 Service 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 chapter Maintenance and
special work" in the VDMA brochure
Safety manual Concrete delivery and placing machines".
The safety regulations in the Operating Instructions must also be folĆ
lowed for all maintenance 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 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_083_1011EN



Safety regulations

2.1 Basic principle The safety regulations in the Operating Instructions for this machine
apply whenever the machine is operated.

Danger
There is an increased risk of accidents during a special operation.
You may only carry out the activities described in these service inĆ
structions if:
ć you have been trained for these activities by the machine manuĆ

facturer
ć you have been authorized for these activities by the machine operĆ

ating company

2.1.1 Exclusion of liability We state here expressly that Putzmeister accepts no liability for damĆ
age arising from incorrect or negligent operation, servicing or mainĆ
tenance or as a result of use contrary to the designated use. This
statement is particularly valid for modifications to, additions to and
customization of the machine that are liable to compromise safety.
The guarantee will no longer be valid in such cases.

BP03_084_1011EN 2ĂĊĂ1

Safety regulations

2.2 Requirements for In the capacity of operator, it is your responsibility to provide all the
special work necessary information to the personnel concerned before special
work or maintenance work is carried out. Someone should be nomiĆ
nated as the person responsible for this.

Carry out the maintenance and inspection operations and comply
with intervals specified in the Operating Instructions, including specĆ
ifications for the replacement of parts and equipment. These actiĆ
vities must be carried out by qualified personnel only.

Workshop equipment appropriate to the task in hand is absolutely
necessary for the execution of maintenance work.

Secure a wide area around the maintenance area as far as is
necessary.

A machine completely shut down for maintenance and repair work
must be secured against being restarted inadvertently:
− Lock the main control devices and remove the key.
− If a main switch is fitted, attach a warning plate to it.

Only carry out maintenance work if the machine is parked on level
and sufficiently supporting ground and is secured against rolling
away.

Use specially designed or otherwise safety−oriented climbing aids
and working platforms when carrying out assembly work above head
height. Never use machine parts as climbing aids. Keep all handĆ
grips, steps, railings, platforms and ladders free from dirt, snow and
ice.

2ĂĊĂ2 BP03_085_1501EN

Safety regulations

Carefully secure individual parts and large assemblies to lifting gear
when carrying out a replacement operation. Use only suitable and
technically perfect lifting gear and suspension systems with adĆ
equate lifting capacity. Never stand under suspended loads.

The fastening of loads and instruction of crane operators should be
entrusted to experienced persons only. The signaller must be within
visual range of or in voice contact with the crane operator.

Observe national regulations when working with lifting gear.

Work on chassis, braking and steering systems must only be carried
out by qualified personnel trained for such work.

Clean the machine, especially connections and threaded unions, of
any traces of oil, fuel or preservatives before carrying out maintenĆ
ance or repair work. Do not use aggressive cleaning agents. Use
lint−free cleaning rags.

Bolted connections that you have loosened for carrying out maintenĆ
ance and repair work must always be retightened to the specified
torque.

Do not open gas−filled spring elements, as used on maintenance
flaps, for instance. The spring elements are filled with gas under high
pressure which can escape explosively if you attempt to open them.
Relieve the tension on systems under mechanical stress.

Be aware of hot functional fluids and surfaces (hydraulic fluid, hyĆ
draulic fluid radiator, etc.).

Ensure that all functional fluids, consumables and replaced parts are
disposed of safely and with minimum environmental impact.

BP03_085_1501EN 2ĂĊĂ3

Safety regulations

2.3 Welding Only qualified personnel commissioned by the manufacturer may
carry out welding work on the placing boom, on the supports or on
other components which are important for safe operation. The work
must be inspected by an authorized inspector.

Always attach the earth cable of the welding unit directly to the comĆ
ponent which is being welded. The welding current must not flow
through hinges, cylinders, etc. Significant damage may be caused in
the event of a flash over.

2ĂĊĂ4 wz0215

Electronic components can be destroyed by stray voltage during arc
welding processes. For this reason:
− Disconnect the remote control cable from the control console.
− Disconnect all cables leading to the receiver of the radio remote

control system.
− Close connector sockets with caps.
− Disconnect the positive and negative leads from the battery.

Only carry out welding, flame cutting and grinding operations on the
machine if this is expressly approved by the manufacturer.

Clean the machine and its surroundings of dust and flammable subĆ
stances and make sure that the premises are adequately ventilated
before carrying out welding, flameĆcutting and grinding operations
(danger of explosion).

Only qualified personnel should carry out welding work on the fuel
and oil reservoirs in accordance with the manufacturer’s specificaĆ
tions.

BP03_085_1501EN

Safety regulations

2.4 Working on the Only carry out maintenance and repair work on the placing boom if
placing boom the placing boom is folded or properly supported, the engine is
switched off and the support legs are secured.
2.5 Safety-relevant
components Support the placing boom arms before starting work on the valves,
cylinders or hydraulic lines on the boom.

The delivery line was installed without tension with the placing boom
in the driving position and can only be replaced without difficulty in
this condition. Stresses may be generated on folding if the delivery
line is replaced when the placing boom is unfolded.

Do not remove the whole delivery line but exchange the delivery
arm, e.g boom arm by boom arm. Otherwise, the pivot points of the
new delivery line will have to be redetermined using special equipĆ
ment.

Following substantial changes, placing booms must be inspected by
an authorized inspector before recommissioning.

Some of the manufacturer’s spare parts, such as pumps, valves and
controller cards are supplied from the works with a basic setting.
These must be adjusted (set) in accordance with the information on
the circuit diagram or machine card after installation in the machine.

Parts relevant to safety and adjustable devices (pressure limiting
valve, potentiometer, fluid flow limiter, hydraulic cylinders, etc.) must
only be repaired, replaced or adjusted by After Sales Service perĆ
sonnel. Seals must only be removed by the manufacturer’s After
Sales Service personnel. Modifications to the machine data (in parĆ
ticular, increasing pressures, modifying speeds, etc.) are not perĆ
mitted.

BP03_085_1501EN 2ĂĊĂ5

Safety regulations

2.6 Software If a machine is equipped with software, the software may only be
used as is provided for in the manufacturer’s Operating Instructions.

Only persons authorized by the manufacturer may intervene in the
machine’s software. This also applies to updates.

Unauthorized interventions in the machine’s software may lead to seĆ
vere damage and accidents.

2.7 Protective and safety Any safety equipment removed for maintenance purposes must be

equipment refitted and checked immediately upon completion of this work.

All equipment required for safety and accident prevention (warning
signs and information plates, grilles, guards, etc.) must be in place.
Such equipment must not be removed, modified or damaged.

Keep all warning signs and information plates on the machine comĆ
plete and in a perfectly legible condition.

It is your responsibility as operator to ensure that any warning signs
and information plates that have been damaged or rendered illegible
are replaced without delay.

2ĂĊĂ6 BP03_085_1501EN

Safety regulations

2.8 Electrical power Work on electrical systems or operating equipment must only be carĆ
2.8.1 General ried out by qualified personnel. For further information on machines
operated on the site power supply, see also section 2.8.3, entitled
Power at the construction site".

Machine components which are to undergo maintenance work must
be deĆenergized. Ensure that disconnected machine components
cannot be restarted. First of all, you must check that deĆenergized
parts are indeed deĆenergized, then earth and shortĆcircuit them and
isolate adjacent live parts.

Disconnect the negative lead from the battery before starting any
work on the electrical system of machines with an internal combusĆ
tion engine. When reconnecting, connect the positive terminal first,
and then the negative terminal.

Before starting work on highĆvoltage assemblies and after cutting the
power supply, you must connect the supply cable to earth and shortĆ
circuit the components, particularly the capacitors, with a rodĆtype
earth electrode.

If work is to be carried out on live parts, the presence of a second
person is required who can switch off the power supply to the maĆ
chine in the event of an emergency. Secure the working area with a
red−and−white safety chain and a warning plate. Use insulated tools
only.

BP03_085_1501EN 2ĂĊĂ7

Safety regulations

2.8.2 Electrical components Control cabinet, motor and control elements are protected as stanĆ
dard at least to degree of protection IP 54. IP 54 means:
− Complete protection against contact with live components or interĆ

nal moving parts. Protection against damaging dust deposits.
− Water spraying on the equipment from random directions shall not

have a damaging effect.

2.8.3 Power at the con- Use only original fuses with the specified current rating. The electriĆ
struction site cal system can be destroyed by overrated fuses or bridging. You
must switch off the machine immediately if a fault occurs in 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 mains power supply.

Only qualified personnel may work on electrical systems with an opĆ
erating voltage in excess of 25Ăvolts alternating voltage or 60Ăvolts
direct current. Only such qualified personnel may install, connect,
disconnect and open electrical control cabinets.

An electric shock (possibly with fatal consequences) may be the reĆ
sult of touching machines with electric motors or contact with other
electrical cables if the electrical connection has not been made
properly or the supply cable is damaged.

2ĂĊĂ8 BP03_085_1501EN

Safety regulations

2.9 Hydraulic systems Work on hydraulic systems must only be carried out by qualified perĆ
2.9.1 General sonnel.

Always wear your personal protective equipment when carrying out
work on the hydraulic system. Escaping fluid is toxic and can penĆ
etrate the skin.

Injection through the skin is a major medical emergency situation. In
the event of injuries caused by pressurized fluid, inform the company
medical officer and call a medical specialist immediately. This also
applies for injuries which may seem only slight. Hydraulic fluid which
has penetrated underneath the skin must be removed immediately.
Otherwise, there is a risk of life−endangering impairment to blood
circulation and infections.

Parts of the system and pressure lines which are to be opened (hyĆ
draulic, pneumatic, and delivery lines) must be depressurized acĆ
cording to assembly descriptions before repair work is started.

Work only on depressurized systems. Switch the hydraulic pump
drive and the engine off, otherwise there is a risk of injury caused by
functional fluids escaping under pressure. Where a hydraulic accuĆ
mulator is fitted, open the accumulator dump valve to prevent any
movements of the machine as a result of the residual pressure.
Modifications to the hydraulic accumulator are prohibited.

Be aware that enclosed hydraulic fluid can remain under pressure
for a certain length of time. Do not open any hydraulic systems if
they are under load from an external force (particularly from a raised
placing boom).

Route and install hydraulic lines in accordance with current enginĆ
eering standards. Ensure that connections are not interchanged. The
fittings, lengths and quality of the hoses must comply with technical
requirements.

BP03_085_1501EN 2ĂĊĂ9

Safety regulations

2.9.2 Replacing hydraulic You must carefully bleed the hydraulic system after any maintenance
hoses work, otherwise there is a risk of injury caused by swinging and teleĆ
scopic support legs extending rapidly, the placing boom lowering,
2.10 Noise emissions etc. Open vent valves very carefully until hydraulic fluid starts to esĆ
cape. You should on no account open vent valves further than
necessary or go so far as to remove them.

Damaged hydraulic lines must be replaced rather than repaired. You
must replace damaged or saturated hydraulic hoses immediately.
Spurting hydraulic fluid may cause injury and fire.

During retesting, hydraulic hoses must be checked by a subject exĆ
pert for outer damage. The retest must be recorded in the check
book. The operator must have hydraulic hoses replaced if they show
signs of external damage.

The place of work in normal operation is with the remote control. For
this reason, it is not possible to specify a particular place of work for
the machine operator. Take the values for the sound pressure level
and sound power level from the machine Operating Instructions.

Wear suitable personal protective equipment in the vicinity of the maĆ
chine.

As the operator, you must instruct your personnel to always wear
their personal ear protection. You are responsible for ensuring that
your personnel comply with this regulation.

All soundproofing equipment must be fitted and in perfect condition.
All soundproofing equipment must be closed during operation. A
high sound level can cause permanent hearing damage.

2ĂĊĂ10 BP03_085_1501EN

Safety regulations

2.11 Exhaust fumes Vehicle exhaust gases contain constituents which can be lethal or
2.12 Functional fluids carcinogenic. Operate internal combustion engines and fuel−operĆ
ated heating systems only in adequately ventilated premises. Before
starting up the engine in enclosed spaces, make sure that there is
adequate ventilation and direct the exhaust gases away from the
place of work.

Wear personal protective clothing and equipment for all work in
which exhaust gases or particles of building material can enter the
body through the respiratory passages. Comply with the information
issued by the manufacturer of the building material.

When handling oils, greases and other functional fluids, observe the
Safety Manual applicable to the product concerned (see the safety
data sheet).

Oils, fuel and other functional fluids may be hazardous to health
upon contact with the skin, etc. You must, therefore, always wear
personal protective clothing and equipment when you are handling
toxic, caustic or other functional fluids that are hazardous to health
and always take note of the manufacturer’s information.

wz0146

Take care when handling toxic and caustic functional fluids (brake
fluid, battery acid, water glass, concrete set accelerating admixĆ
tures, cement, etc.). Building materials containing cement have a
highly alkaline effect when they react with water (and also with perĆ
spiration). Admixtures are toxic and caustic.

BP03_085_1501EN 2ĂĊĂ11

Safety regulations

Cleaning agents, concrete release agents, preserving agents etc.
propelled by compressed air can cause very serious damage to the
respiratory tract if a respiratory protection mask is not worn. Spray
mist enters the lungs very easily.

Frequent injuries are eye injuries caused by concrete spatter, water
glass or other chemical substances.

Take care when handling hot functional fluids and consumables (risk
of burning or scalding).

Have used operating equipment and functional fluids such as filters,
batteries, oil, brake fluid, etc. disposed of properly. Used cleaning
rags should also be disposed of properly.

2.13 Disposal of the ma- wz0186
chine
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 particular:
− Remove the functional fluids, particularly hydraulic fluids, engine

oils, fuel, brake fluid, concrete admixtures, any environmentally
hazardous functional fluids or functional fluids which are hazardĆ
ous in any other way, and dispose of these correctly.
− Remove the operating equipment, particularly the hydraulic fluid
reservoir, hydraulic cylinder, hydraulic fluid radiator, hydraulic lines
and hoses and other components which may contain residual
functional fluids, and dispose of these correctly.
− Remove the steel structure and dispose of it correctly, e.g. by reĆ
cycling.
− Dispose of the truck or the drive unit correctly.

2ĂĊĂ12 BP03_085_1501EN

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 for function checks

BP15_001_1202EN



Safety functions

3.1 Overview of the safety Depending on the type of machine and its equipment, the following

equipment safety equipment may be fitted. Please see the machine card for deĆ

tails about which safety equipment your machine has been fitted

with. Carry out checks on the existing safety equipment according to

the following descriptions within the specified intervals.

3.1.1 Active safety functions

Intervals for inspection by a Interval for function check
subject expert

EMERGENCY STOP function Annually Before the machine is used
Agitator safety cutout Annually each time
Support control block Annually
Joysticks for remote control / Before the machine is used
boom control block each time

Before the machine is used
each time

Annually Before the machine is used
each time

3.1.2 Passive safety function Intervals for inspection by a Interval for function check
subject expert
Separating protective deĆ
vices Annually each time a separating proĆ
Grille tective device is removed

Annually Once a month

3.1.3 Organizational measures Intervals for inspection by a Interval for function check
Plates subject expert

Annually Once a month

BP15_003_1412EN 3ĂĊĂ1

Safety functions

3.1.4 Safety-related parts (SRPs)
SafetyĆrelated parts (SRP) are components that ensure the safety of
the machine functions. They are specially marked on spare parts
sheets. When a spare part that can be used as an SRP is ordered, it
is delivered in separate, clearly labelled packaging.
Danger
If an SRP is not properly maintained, repaired or replaced, this may
cause safety functions to malfunction. This creates a lethal danger.
An SRP must only be maintained, repaired or replaced by qualified
personnel who have been authorized by Putzmeister.

SRP marking

3

Spare parts sheet BP15_003_1412EN 1

Spare part packaging

3ĂĊĂ2 BP15_003_1412EN

123 4 Safety functions

5

Pos.0 Illustration BP15_003_1412EN 2
1 Icons: Asterisk *"
2 Icons: Exclamation mark !" Meaning
Item not available for order
3 Number Safety−related part (SRP)
Service life of the SRP [years]
4 Symbol: Hourglass" e.g. 10" = 10 years
Service life of the SRP
5 Graphic Example illustration: Spare parts sheet
0.5 XXXXX−XXXX" Safety−related part

Note
For every safety−related part (SRP), the manufacturer has specified
the service life. When this service life has elapsed, the safety−related
component must be replaced.

BP15_003_1412EN 3ĂĊĂ3

Safety functions

3.1.5 Safety components

The following listed parts are defined as safety components. This inĆ
cludes the following components in particular:
− LoadĆholding valves (monoblock, duoblock)
− Pressure limiting valves

Danger
If a safety component is not properly maintained, repaired or reĆ
placed, this may cause safety functions to malfunction. This creates
a lethal danger. A safety component must only be maintained, reĆ
paired or replaced by qualified personnel who have been authorized
by Putzmeister.

3.1.6 Parts with increased maintenance requirements

The following listed parts are defined as parts with increased mainĆ
tenance requirements. This includes the following components in
particular:
− Accumulator
− Accumulator bladder
− Gas valve insert for accumulator

Danger
If a component with increased maintenance requirements not
properly maintained, repaired or replaced, this may cause safety
functions to malfunction. This creates a lethal danger. A component
with increased maintenance requirements must only be maintained,
repaired or replaced by qualified personnel who have been authorĆ
ized by Putzmeister.

3ĂĊĂ4 BP15_003_1412EN

Safety equipment

3.2 EMERGENCY STOP function

Intervals for inspection by a ISO 13849Ć1:2006 category 1 PL c
subject expert annually
Before the machine is used each time
Intervals for function checks

3.2.1 Description As soon as an EMERGENCY STOP button is pressed, all dangerous
of the functions machine movements stop. The following actions are triggered when
the relevant components are present on the machine:

System Safety action

Pump − The accumulator dump valve is opened and the
accumulator is emptied.
Boom and
support legs − The agitator stops.
Mixer drum − The transfer tube stops.

Rotor pump − The boom control block is disconnected.
− The boom and support leg control do not work.
Remote con-
trol − The hydraulic pump control chambers are
switched at the same pressure.

− The mixer drum stops.

− The hydraulic pump control chambers are
switched at the same pressure.

− The rotor pump stops.

− The supply voltage to the entire radio remote
control system is switched off, all indicator
lamps on the radio remote control unit go out.

− The EGDĆRC switches off.
− The supply voltage, apart from the horn, is

switched off at the cable remote control system,
and the Fault" indicator lamp is lit on the cable
remote control unit.

BP15_004_1202EN 3ĂĊĂ5

Safety equipment

System Technical action
Truck
− Engine speed drops to idle.
Pump − It is no longer possible to set the engine speed

electrically.

− The EMERGENCY STOP" symbol flashes on
the EGD.

− Variable main pumps swing back, the delivery
pistons come to a halt.

3.2.2 Function check It is only possible to intervene rapidly in the event of danger if all the
EMERGENCY STOP buttons are functioning.

" Switch the pump and agitator on.

" Operate a boom function.

" Press one of the EMERGENCY STOP buttons.
å The agitator and the boom must come to a halt immediately.
å The accumulator is emptied.

" Check all EMERGENCY STOP and STOP buttons on the maĆ
chine and on the remote control in the same way.

3ĂĊĂ6 BP15_004_1202EN

Safety equipment

3.3 Agitator safety cutout ISO 13849Ć1:2006 category 1 PL c
annually
Intervals for inspection by a Before the machine is used each time
subject expert
Intervals for function checks

Danger
Risk of injury when the agitator is operating and the 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 run or the transfer tube switching
over when the grille is open.

You must therefore check the function of the agitator safety cutout
before you start each pumping job.

You must stop work if you open the grille, but
ć the agitator continues to run, or
ć the transfer tube continues to switch, or
ć the concrete pump does not run to its end position.

BP15_012_1504EN 3ĂĊĂ7

Safety equipment

3.3.1 Description of the This machine is fitted with an agitator safety cutout (RSA). As soon
functions as you open the grille, the signal between the transponder and readĆ
ing head is broken. This causes the agitator to halt and the pressure
to be dumped from the accumulator, i.Ăe. the transfer tube will no
longer be able to switch over. In addition, the delivery pistons return
to the end position and the concrete pump halts.

12 3

BP15_012_1504EN 1

No. 0 Designation
1 Reading head (on the hopper − example illustration)
2 LED, green and red
3 Transponder (on the grille)

Safety action:
− The accumulator dump valve is opened and the accumulator is

emptied.
− The agitator stops.
− The transfer tube stops.

Technical action:
− The delivery pistons return to the end position
− The concrete pump stops

3ĂĊĂ8 BP15_012_1504EN

Safety equipment

3.3.2 Function check

BP15_012_1504EN 2

" Open the grille with the concrete pump running.
å The transponder signal is broken.
å The agitator must come to a halt immediately.
å The transfer tube must no longer switch over.
å The concrete pump must run to the end position and halt.

Safety action:
å The agitator must come to a halt immediately.
å The hydraulic fluid pressure in the accumulator is dumped
(see the pressure gauge).
å The transfer tube must no longer switch over.

Technical action:
å The concrete pump must run to the end position and halt.

Hopper type Opening [mm]
RS90x 140
RS907L 210
TMP62CS 159
TMP64Q 89
RS401 40

BP15_012_1504EN 3ĂĊĂ9

Safety equipment

3.3.3 Acknowledging the The agitator is secured against unexpected restarts. When the maĆ
agitator safety cutout chine is set up, and when the agitator safety cutout is triggered, it
must be acknowledged before the concrete pump can be switched
back on.

Danger
Risk of injury when the agitator is operating and the transfer tube is
switching. Before acknowledging the agitator safety cutout, check
that noĆone is in any danger.

Note
You must acknowledge the agitator safety cutout and switch the conĆ
crete pump off and back on again to restart it.

1

1

BP15_012_1504EN 3

No. 0 Designation
1 Acknowledging the agitator safety cutout

" Activate the Acknowledge the agitator safety cutout" toggle
switch.

3ĂĊĂ10 BP15_012_1504EN

Safety equipment

3.4 Support control block ISO 13849Ć1:2006 category 1 PL c
annually
Intervals for inspection by a Before the machine is used each time
subject expert
Intervals for function checks

3.4.1 Description The support control block is designed as an enabling function, i.e. to
of the functions execute a function, you must operate the preselect lever and the
corresponding function lever simultaneously. The hydraulic support
Example valves are springĆloaded, i.e. the valves are automatically reset to
the zero position when you release the levers.

6
1

2 34 5 22104901

No. 0 Designation

1 Preselect lever for support function ON/OFF
2 Raise and lower forward support foot
3 Raise and lower rear support foot
4 Extend and retract forward support leg
5 Swing rear support leg out and in
6 EMERGENCY STOP button

BP15_006_1202EN 3ĂĊĂ11

Safety equipment

3.4.2 Function check You can only support the machine correctly when the control block
Precondition support is fully functional.

Execution − Machine in driving position
− Parking brake applied
− Engine running
− Power takeĆoff switched on
− Support leg unlocked
− Remote control support function switched on

Note
Once a lever has been released, the valve must reset to the zero
position of its own accord.

" Extend or swing all support legs approximately halfway out,
one after the other.
å The relevant support leg must stop moving as soon as you
release one of the levers.

" Extend each of the support feet slightly, one after the other.
å The relevant support foot must stop moving as soon as you
release one of the levers.

" Only operate the support function preselect lever.
å The support legs and feet must not move.

" One after another, press each individual support leg valve in
both directions without operating the preselect lever.
å The support legs and feet must not move.

3ĂĊĂ12 BP15_006_1202EN

Safety equipment

3.5 Remote control/boom control block joysticks

Intervals for inspection by a ISO 13849Ć1:2006 category 1 PL c
subject expert annually
Before the machine is used each time
Intervals for function checks

3.5.1 Joystick function The remote control joysticks are devices with selfĆacting resets
description (switches). As soon as you release a deflected joystick, it is autoĆ
matically reset to the zero position.

1

BP15_007_1202EN 1

No. 0 Designation
1 Joystick

BP15_007_1202EN 3ĂĊĂ13

Safety equipment

3.5.2 Function description The boom control block is designed as an enabling function, i.e. for
for boom control a function to be executed, the remote control signal operates the opĆ
block erating mode selector valve and the corresponding boom section
valve at the same time. The hydraulic boom section valves are
springĆloaded, i.e. the valves are automatically reset to the zero posiĆ
tion when you release the remote control joystick.

Example diagram of
a boom control block

3 1
2
No. 0 Designation
1 Input module BP15_007_1202EN 2
2 Operating mode selector valve
3 Boom section valve

3ĂĊĂ14 BP15_007_1202EN

Safety equipment

3.5.3 Function check The machine can only be operated safely if the remote control and
boom control block are fully functional.
Precondition
Execution Note
Perform the function check with both the radio and cable remote
controls.

If you are using the cable remote control, the operating mode selecĆ
tor valve responds with a delay of approx. 1 second.

− Parking brake applied
− Power takeĆoff switched on
− Machine fully supported
− Engine running

" Switch on the remote control.
" Raise the arm assembly a few metres.
" Operate the boom control joysticks briefly several times while

observing the valves on the boom control block.
å The boom section valve being actuated and the operating
mode selector valve should move.
å The relevant LED should light up in the corresponding coĆ
lour (see the table below).
" Release the joystick after each function.
å The joystick should reset to the zero position of its own acĆ
cord.
å The boom section valve and operating mode selector valve
should reset to the zero position of their own accord.

BP15_007_1202EN 3ĂĊĂ15

Safety equipment

5
4

3
2
1

BP15_007_1202EN 3

No. 0 Designation

1 Boom section valves arms up − down
2 Rotate the boom section valve
3 Operating mode selector valve
4 Input module
5 LED

LED colours

Function LED
Support leg function red
Boom function green
Slew boom to the left green
Slew boom clockwise red
Arms up red
Arms down green

3ĂĊĂ16 BP15_007_1202EN

Safety equipment

3.6 Protective devices ISO 13849Ć1:2006 category 1 PL c
annually
Intervals for inspection by a Before the machine is used each time
subject expert
Intervals for function checks

3.6.1 Description A protective device is an obstacle (e.g. cover) located between the
of the functions machine operator and the danger zone.

3.6.2 Function check Below you will see a sample diagram of a truckĆmounted concrete
pump and the protective devices installed.

" Check whether the protective devices are present, fully funcĆ
tional and securely mounted.

BP15_008_1202EN 3ĂĊĂ17

Safety equipment

1 23 4 5 6 7 8 3 9 10 11 12 13

BP15_008_1202EN 1

No. 0 Safety devices

1 Cardan shaft cover
2 Snaplock on the support leg
3 FourĆpoint bearing/slewing ring cover
4 Diagonal box/support leg covers
5 Side underride protection
6 Retaining rope on the end hose
7 Securing cotter pins on delivery line couplings
8 Water box cover
9 Boom cradle cover
10 Cover over the switch cylinders
11 Spray guard on the hopper
12 Grille
13 Rear underride protection

Not illustrated:
Catch basket (for cleaning with compressed air)
Protective bell (for divided end hose)
Grille over the fan wheel on the compressor

3ĂĊĂ18 BP15_008_1202EN