Manual safety regulation_EN

Safety equipment

3.7 Grille ISO 13849Ć1:2006 category 2 PL d

Intervals for inspection by a annually
subject expert
Intervals for function checks Once a month
Intervals for replacement As soon as a bar has a residual material thickness of 50% of
height or width, at any point.

3.7.1 Description The grille is a passive safety function (protective device). For techniĆ
of the functions cal reasons, the bar spacing is selected in such a way that allows
concrete with defined particle sizes to flow into the hopper. The bars
are subject to natural wear.

Danger
If the grille is defective, there is a risk that the operator could be
caught in the agitator and seriously injured. Therefore, make sure
that the grille remains fully functional at all times. If the residual maĆ
terial thickness is reached, you must have the grille replaced by
qualified personnel authorized by Putzmeister.

Once the grille has been replaced, the agitator safety cutout must be
reset. This may only be performed by qualified personnel authorized
by Putzmeister.

BP15_009_1202EN 3ĂĊĂ19

Safety equipment

3.7.2 Function check

BP15_009_1202EN 1

" Measure the width (W) and height (H) of the bars in an area
with high wear, preferably in the middle of the grille.

" Measure the width (W) and height (H) of the bars in an area
with low wear (the edge of the grille).

" Compare the values measured.

Note
You must have the grille replaced if one of the residual material thickĆ
nesses is less than 50% of the original material thickness.

" Inspect the grille for any other damage (broken bars, cracked
seams, etc.).

Note
You must have the grille repaired or replaced if you detect any damĆ
age.

3ĂĊĂ20 BP15_009_1202EN

Safety equipment

3.8 Plates annually
Once a month
Intervals for inspection by a
subject expert
Intervals for function checks

3.8.1 Description Plates on the machine warn operators of dangers that cannot be preĆ
of the functions vented by means of the design.

Note
You will find the locations of the plates on the machine circuit diaĆ
grams, which indicate which plate should be affixed where.

3.8.2 Function check

" Check whether the plates that are required according to the
plate location plan have been affixed on the machine and are
legible.

" Replace any missing, damaged or illegible plates with new
ones.

BP15_010_1202EN 3ĂĊĂ21



4 Special modes of operation

The machine’s special operating modes are described in this
chapter. Special operating modes are, in particular:
− Operation in situations of increased risk
− Operation with limited functions
Danger
There is an increased risk of accidents during special operations.
Special operations must only be carried out 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

BP16_001_1202EN



Special modes of operation

4.1 Emergency operation The hydraulic control valves are built into the pump control system.

– pump function They are only for emergency manual operation of the machine when

the control system fails.

1
2

3
4

5

6

BP16_008_1208EN 1

No. 0 Designation

1 Accumulator
2 Agitator and water pump control block
3 Transfer tube changeĆover valve
4 Delivery cylinder emergency control lever
5 Transfer tube damping cock
6 Accumulator dump valve

BP16_008_1208EN 4ĂĊĂ1

Special modes of operation

Special features of the pump control system

Accumulator dump This machine is fitted with an electrically operated agitator safety
valve cutout. The accumulator pressure is dumped through an accumulaĆ
tor dump valve and the transfer tube halts, among other measures,
as soon as the grille is opened.

Delivery cylinder If the control system fails, you can operate the delivery cylinders
emergency control using the emergency control lever.
lever
The location of the control block depends on the machine. A deĆ
Agitator and water scription of emergency operation can be found on the following
pump control block pages.

4ĂĊĂ2 BP16_008_1208EN

Special modes of operation

4.2 Emergency operation You can operate the agitator and the water pumps manually from the

of the agitator and hydraulic control block illustrated below if the control panel has

water pumps failed.

4 2
3

1

5

BP16_003_1209EN 1

No. 0 Designation
1 Agitator/water pumps shutĆoff valve
2 Agitator changeĆover valve
3 Water pump emergency operation
4 Direction of agitator rotation emergency operation
5 Agitator emergency operation

BP16_003_1209EN 4ĂĊĂ3

Special modes of operation

Special features of the hydraulic control block

Flushing water pump To operate the flushing water pump in emergency operation mode,
emergency operation hold down the water pumps emergency operation control on the
shutĆoff valve.

Note
To operate the highĆpressure water pump (optional) in emergency
operation mode, you must also hold down the emergency operation
valve on the highĆpressure water pump.

Agitator emergency To operate the agitator in emergency operation mode, hold down the
operation agitator emergency operation control on the shutĆoff valve. To
change the direction of rotation, you must also hold down the agitaĆ
tor changeĆover valve.

4ĂĊĂ4 BP16_003_1209EN

Special modes of operation

4.3 Boom control block The arm assembly can be operated manually at the boom control

(emergency control block in the event of a remote control malfunction.

lever for boom func-

tions) Danger

Lock the stowage compartment to ensure that unauthorized persons

are not able to gain access to the boom control block.

Machines which offer support monitoring do not have a feature to
mechanically safeguard the working area.
If support monitoring is defective (in process observation mode 2),
this poses lethal danger, since the machine may topple over.

If, when support monitoring is defective, the arm assembly is turned
outside of the defined working areas using the emergency control
levers, the arm assembly will slew into the prohibited area and the
machine may overturn. When turning the arm assembly using the
emergency control levers, attention must always be paid to the workĆ
ing area.

Machines which offer the OSS function do not have a feature to
mechanically safeguard the OSS range. If the arm assembly is
turned too far with the emergency control levers, the arm assembly
will slew into the prohibited area, and the machine may overturn.
When turning the arm assembly with the emergency control levers,
always pay attention to the OSS range.

Arm assemblies with slewing gear transmissions have no mechanĆ
ical stop to limit turning. If the arm assembly is turned too far with the
emergency control levers, the hydraulic hoses of the arm assembly
will wrap around the slewing head and rip off. When turning the arm
assembly with the emergency control levers, always pay attention to
the hydraulic hoses of the arm assembly.

BP16_040_1501EN 4ĂĊĂ5

Special modes of operation

Note
The boom control block can only be operated after the guard has
been removed. If the remote control is not working, you must control
the arm assembly using the emergency control levers on the boom
control block. To do this, push the preselect lever on the boom conĆ
trol block in the direction of the Boom" symbol.

Depending on the mounting position, the emergency control levers
of the boom control block may face upwards or downwards. The
lever assignment sequence may also be from right to left or vice
versa. It may also be the case that the control block is installed roĆ
tated through 90°. Familiarise yourself with the functions of the conĆ
trol block by reading the notices affixed on site.

4ĂĊĂ6 BP16_040_1501EN

Special modes of operation

4.3.1 Example illustration of a boom control block
Example illustration of a
boom control block

12345 67

No. 0 Designation BP16_040_1501EN 1
1 Support or boom function On − Off
2 Slew boom antiĆclockwise/clockwise
3 Arm 1 up/down
4 Arm 2 up/down
5 Arm 3 up/down
6 Arm 4 up/down
7 Arm 5 up/down

BP16_040_1501EN 4ĂĊĂ7

Special modes of operation

4.4 Recovering the ma- If a fault occurs on the machine and cannot be rectified immediately,
chine after faults you must stop site use and take steps to recover the machine. The
occur delivery system may become damaged if concrete sets in it.

Note
Recovery of the machine is a special operating mode. This special
operating mode is not suitable for continuing site use.

Danger
There is an increased risk of accidents during special operations.
Special operation must only be carried out 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

The machine’s EMERGENCY STOP buttons do not work while the
machine is being recovered (e.g. in the event of a power failure). For
this reason, you must cover all EMERGENCY STOP buttons for the
duration of machine recovery.

Have a second person help you, as the steps required can be better
carried out with two people.

4ĂĊĂ8 BP16_039_1501EN

Special modes of operation

4.4.1 Recovery with on- As long as the machine’s hydraulic drive unit is working, you can reĆ
board equipment cover the machine using onĆboard equipment.

Emergency operation The pump control system is equipped with hydraulic control valves
of pump function which can be operated by hand. They are only for emergency manĆ
ual operation of the machine when the control system fails.

1

BP16_039_1501EN 1

No. 0 Designation
1 Guard

" Cover all EMERGENCY STOP buttons on the machine.
" Remove the guard above the pump control system.

BP16_039_1501EN 4ĂĊĂ9

Special modes of operation

1
2

3
4

5

6
7

BP16_039_1501EN 2

No. 0 Designation

1 Accumulator
2 Agitator and water pump control block
3 Transfer tube change−over valve
4 Delivery cylinder emergency control lever
5 Transfer tube damping cock
6 Accumulator dump valve
7 Accumulator pressure gauge

" Press the delivery cylinder emergency control lever to the left
or right.
å The corresponding delivery cylinder starts to move.

" Once the delivery cylinder has reached its end position, press
and hold the accumulator dump valve.

" Once the accumulator is filled (see accumulator pressure
gauge), press the transfer tube changeĆover valve.
å The transfer tube switches over.

" Pump the concrete out of the delivery line, back into the
hopper.

4ĂĊĂ10 BP16_039_1501EN

Special modes of operation

Emergency operation The arm assembly can be operated manually at the boom control

of boom functions block in the event of a remote control malfunction.

Danger
Lock the stowage compartment to ensure that unauthorized persons
are not able to gain access to the boom control block.

Machines which offer support monitoring do not have a feature to
mechanically safeguard the working area.
If support monitoring is defective (in process observation mode 2),
this poses lethal danger, since the machine may topple over.

If, when support monitoring is defective, the arm assembly is turned
outside of the defined working areas using the emergency control
levers, the arm assembly will slew into the prohibited area and the
machine may overturn. When turning the arm assembly using the
emergency control levers, attention must always be paid to the workĆ
ing area.

Machines which offer the OSS function do not have a feature to
mechanically safeguard the OSS range. If the arm assembly is
turned too far with the emergency control levers, the arm assembly
will slew into the prohibited area, and the machine may overturn.
When turning the arm assembly with the emergency control levers,
always pay attention to the OSS range.

Arm assemblies with slewing gear transmissions have no mechanĆ
ical stop to limit turning. If the arm assembly is turned too far with the
emergency control levers, the hydraulic hoses of the arm assembly
will wrap around the slewing head and rip off. When turning the arm
assembly with the emergency control levers, always pay attention to
the hydraulic hoses of the arm assembly.

BP16_039_1501EN 4ĂĊĂ11

Special modes of operation

Note
The boom control block can only be operated after the guard has
been removed. If the remote control is not working, you must control
the arm assembly using the emergency control levers on the boom
control block. To do this, push the preselect lever on the boom conĆ
trol block in the direction of the Boom" symbol.

Depending on the mounting position, the emergency control levers
of the boom control block may face upwards or downwards. The
lever assignment sequence may also be from right to left or vice
versa. It may also be the case that the control block is installed roĆ
tated through 90°. Familiarise yourself with the functions of the conĆ
trol block by reading the notices affixed on site.

4ĂĊĂ12 BP16_039_1501EN

Special modes of operation

Example illustration of a
boom control block

1234567

BP16_039_1501EN 3

No. 0 Designation
1 Preselect lever: Support or boom function On − Off
2 Slew boom antiĆclockwise/clockwise
3 Arm 1 up/down
4 Arm 2 up/down
5 Arm 3 up/down
6 Arm 4 up/down
7 Arm 5 up/down

" Cover all EMERGENCY STOP buttons on the machine.

" Remove the guard (if fitted) above the boom control block.

" Press the preselect lever to boom function".

" Fold in the arm assembly by operating the individual emergĆ
ency control levers.

BP16_039_1501EN 4ĂĊĂ13

Special modes of operation

Emergency operation To be able to operate the support legs, you must push the preselect

of support function lever on the boom control block towards the support function.

Example illustration

1
2

BP16_039_1501EN 4

No. 0 Designation
1 Preselect lever: Support or boom function On − Off
2 Support control block

" Push the preselect lever towards the support function.
" Retract each of the support feet and support legs, one after the

other.

4ĂĊĂ14 BP16_039_1501EN

Special modes of operation

4.4.2 Recovery with an ex- In the event of total failure, you must connect an external hydraulic
ternal hydraulic power power pack in order to be able to recover the machine.
pack
Caution
A maximum output of only 60 l/min is permitted for the emergency
hydraulic supply, as the machine’s hydraulic system will otherwise be
overloaded.

Note
After connecting the emergency hydraulic unit, you can
ć fold in the arm assembly.
ć retract the support legs.

You cannot operate the delivery cylinders in order to pump the conĆ
crete out of the delivery line.

We recommend the following emergency hydraulic unit:
DynajetR 350 mg Plus
This emergency hydraulic unit comes as standard with the necessĆ
ary accessories and is suitable for supplying Putzmeister concrete
pumps in an emergency.

Have a second person help you, as the steps required can be better
carried out with two people.

BP16_037_1501EN 4ĂĊĂ15

Special modes of operation

Connecting an exter- 1 23
nal hydraulic power
pack

65 4 BP16_037_1501EN 1

No. 0 Designation

1 Boom control block
2 Shut−off valve
3 Vacuum−return flow filter
4 External hydraulic power pack
5 Connector for intake line (yellow marking)
6 Connection for pressure line (red marking)

" Lay an intake line and pressure line from the external hydraulic
power pack (4) to the concrete pump.

" Connect the hydraulic power pack intake line to the ConnecĆ
tion for intake line (yellow marking)" (5) on the vacuum return
flow filter (1).

" Open the shutĆoff valve (2) on the intake side of the vacuum
return flow filter (3).

4ĂĊĂ16 BP16_037_1501EN

Special modes of operation

" Plug the end of the pressure line into the filler pipe of the hyĆ
draulic fluid reservoir and bleed the hydraulic pack by pumpĆ
ing a few litres of hydraulic fluid back into the hydraulic fluid
reservoir under low pressure.

" Place a suitable container underneath the boom control
block (1).

" Open the coupling joint in the line to the boom control block
(red marking) (6).

" Connect the hydraulic power pack pressure line to the open
Connection for pressure line (red marking)" (6).
å You can now use the external hydraulic power pack to
pump hydraulic fluid from the concrete pump hydraulic fluid
reservoir into the boom hydraulic circuit.

BP16_037_1501EN 4ĂĊĂ17

Special modes of operation

Emergency operation The arm assembly can be operated manually at the boom control

of boom functions block in the event of a remote control malfunction.

Danger
Lock the stowage compartment to ensure that unauthorized persons
are not able to gain access to the boom control block.

Machines which offer support monitoring do not have a feature to
mechanically safeguard the working area.
If support monitoring is defective (in process observation mode 2),
this poses lethal danger, since the machine may topple over.

If, when support monitoring is defective, the arm assembly is turned
outside of the defined working areas using the emergency control
levers, the arm assembly will slew into the prohibited area and the
machine may overturn. When turning the arm assembly using the
emergency control levers, attention must always be paid to the workĆ
ing area.

Machines which offer the OSS function do not have a feature to
mechanically safeguard the OSS range. If the arm assembly is
turned too far with the emergency control levers, the arm assembly
will slew into the prohibited area, and the machine may overturn.
When turning the arm assembly with the emergency control levers,
always pay attention to the OSS range.

Arm assemblies with slewing gear transmissions have no mechanĆ
ical stop to limit turning. If the arm assembly is turned too far with the
emergency control levers, the hydraulic hoses of the arm assembly
will wrap around the slewing head and rip off. When turning the arm
assembly with the emergency control levers, always pay attention to
the hydraulic hoses of the arm assembly.

4ĂĊĂ18 BP16_037_1501EN

Special modes of operation

Note
The boom control block can only be operated after the guard has
been removed. If the remote control is not working, you must control
the arm assembly using the emergency control levers on the boom
control block. To do this, push the preselect lever on the boom conĆ
trol block in the direction of the Boom" symbol.

Depending on the mounting position, the emergency control levers
of the boom control block may face upwards or downwards. The
lever assignment sequence may also be from right to left or vice
versa. It may also be the case that the control block is installed roĆ
tated through 90°. Familiarise yourself with the functions of the conĆ
trol block by reading the notices affixed on site.

BP16_037_1501EN 4ĂĊĂ19

Special modes of operation

Example illustration of a
boom control block

1234567

BP16_037_1501EN 2

No. 0 Designation
1 Preselect lever: Support or boom function On − Off
2 Slew boom antiĆclockwise/clockwise
3 Arm 1 up/down
4 Arm 2 up/down
5 Arm 3 up/down
6 Arm 4 up/down
7 Arm 5 up/down

" Use suitable means to cover all of the EMERGENCY STOP butĆ
tons on the machine.

" Remove the guard above the boom control block.

4ĂĊĂ20 BP16_037_1501EN

Special modes of operation

BP16_037_1501EN 3

" Open the hinged elbow at the back of the hopper, so that the
concrete can flow out of the delivery line.

" Press the preselect lever to boom function".
" Move the arm assembly to a steeply rising position.

å The concrete flows back out of the delivery line.
" Fold in the arm assembly by operating the individual emergĆ

ency control levers.

BP16_037_1501EN 4ĂĊĂ21

Special modes of operation

Emergency operation To be able to operate the support legs, you must push the preselect

of support function lever on the boom control block towards the support function.

Example illustration

1
2

BP16_037_1501EN 4

No. 0 Designation
1 Preselect lever: Support or boom function On − Off
2 Support control block

" Push the preselect lever towards the support function.

4ĂĊĂ22 BP16_037_1501EN

Special modes of operation

Example of supporting
the control block

6

12 34 5 BP16_037_1501EN 5

No. 0 Designation
1 Preselect lever: Support function On − Off
2 Extend and retract forward support foot
3 Extend and retract rear support foot
4 Extend and retract forward support leg
5 Swing rear support leg out and in
6 EMERGENCY STOP button

" Retract each of the support feet and support legs, one after the
other.

Once the arm assembly and support legs have been folded in, you
can remove the machine from the construction site.

BP16_037_1501EN 4ĂĊĂ23



5 Maintenance

In this chapter you will find information on maintenance work which is
necessary for the safe and efficient operation of the machine.
Following the general maintenance information, you will find the
maintenance cards necessary for this machine. The table of contents
includes a summary of the maintenance cards in numerical order,
you will find an alphabetical summary in the Index of key words
under the entry for Maintenance cards".
We should like here to emphasise expressly that all prescribed
checks, inspections and preventative maintenance work must be
conscientiously carried out. Otherwise, we will refuse to accept any
liability or to honour the warranty. Should you ever be in any doubt,
our After Sales Department is always ready to give you advice and
assistance.

BP09_001_9405EN



Maintenance

5.1 Maintenance intervals The following table shows the intervals for the various maintenance
tasks. The associated maintenance cards can be found further on in
this chapter.

Note
Have the first After Sales service after 100 operating hours carried
out by a Putzmeister After Sales Service engineer. The machine
operator responsible for the machine should be present during this
service.

Assembly Action Every ... operating hours Other
General daily 50 100 250 500 1000 intervals

Hydraulic system Lubricate the truck superĆ weekly
Fluid filter structure

Visual inspection and function D
check on all safety equipment

Check the bolted connections as required
against the tightening torque
table

Visual inspection of electrical D
cabling

Check hydraulic fluid level D
Drain off condensate water D

Visual check of the lines D
(damage/leaks)

Full fluid change (after fluid D
analysis)

Clean fluid sump D
monthly
Check hydraulic cylinder
for leak tightness (visual
inspection)

Check the contamination D
indicator on the filters

Replace the vacuum return flow D as required
filter element

Replace the suction filter Together with the vacuum return flow filter element
element

BP09_019_1403EN 5ĂĊĂ1

Maintenance

Assembly Action Every ... operating hours Other
daily 50 100 250 500 1000 intervals
Gearbox
Transfer gearbox full oil change D annually
Water tank (mineral transmission oil)

Boom pedestal Transfer gearbox full oil change D annually
(synthetic transmission oil)
Transfer tube
Delivery line Agitator gearbox full oil change D
Delivery piston
Parts in contact with concrete Slewing gear transmission D annually
Centralized lubrication system full oil change

Check the water level D

Check the sacrificial anodes annually

Check slewing ring bolts according
to the
retest

Lubricate the swing bearing annually
teeth

Replace sealing ring after
8 years

Wear check D

Check and adjust sealing gap D
Check tightening torque of bolts
D

Safety locks on couplings D

Check the wall thickness D

Check threaded unions and D
securing wire

Check wear on delivery pistons weekly

Wear check D

Check grease level D

5ĂĊĂ2 BP09_019_1403EN

Maintenance

Assembly Action Every ... operating hours Other
daily 50 100 250 500 1000 intervals
HighĆpressure water pump Check oil level
Changing the oil D
Compressor Cleaning the screen in the
water filter D
Cardan shafts (in normal Check the bolted connections
operation) Check oil level weekly
Changing the oil
Cardan shafts (in extreme Clean air intake filter D
operating conditions) Check the bolted connections D
Truck engine Inspection
Truck transmission Lubricate the cross pin D
bearings (if lubrication nipples D
are present) D
Inspection D
Lubricate the cross pin
bearings (if lubrication nipples D
are present)
D

D

In accordance with the truck manufacturer’s maintenance information

Note
For transfer gearboxes that are filled with mineral transmission oil,
the first full oil change must be carried out after 100 operating hours.
After this, a full oil change must be carried out after 500 operating
hours or at least every year.

For transfer gearboxes that are filled with synthetic transmission oil,
the first full oil change must be carried out after 100 operating hours.
After this, a full oil change must be carried out after 1000 operating
hours or at least every year.

BP09_019_1403EN 5ĂĊĂ3

Maintenance

5.2 Residual risks during maintenance, inspection and repair work

5.2.1 Personal protective See the "Safety regulations" chapter for personal protective equipĆ
equipment ment requirements.

Danger
Risk of serious physical injury if personal protective equipment is
not worn. Always wear your personal protective equipment during
maintenance, inspection and repair work. Safety helmet and safety
footwear are a basic requirement. Other personal protective equipĆ
ment is required as listed in the "Safety regulations" chapter.

5.2.2 Personnel Maintenance, inspection and repair work must only be carried out
requirements by qualified personnel. "Qualified personnel" means those who have
completed specialist training for carrying out such work. This training
5.2.3 Auxiliary devices qualifies them to carry out the activity concerned.

Adequate workshop equipment is absolutely necessary for carrying
out maintenance, inspection and repair work.

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

5ĂĊĂ4 BP09_020_1108EN

Maintenance

5.2.4 Residual risks During maintenance, inspection and repair work, there are
particular risks of an accident, because for certain activities,
protective devices must be removed, for example. There follows
a list of residual risks in particular, which may be present during
maintenance, inspection and repair work.

Danger
There is a risk of falling when working above the ground or floor.
You should therefore always ensure that you are secure by using
safety harnesses, railings or walkway barriers. Never use machine
parts as climbing aids. Keep all handgrips, steps, railings, platforms
and ladders free from dirt, snow and ice.

Danger
In the area between the mixer drum and frame, there is a risk of
being pulled in, crushed or injured by shearing. Working in this area
is only allowed if the mixer drum is secured with the mixer drum
holder. Read the operating instructions from the truck mixer manuĆ
facturer for information about this.

Danger
Risk of injury through skin contact with functional fluids
(e.g. hydraulic fluid). Avoid contact with functional fluids.
Wear your personal protective equipment. Take note of the safety
data sheets produced by the manufacturer of the functional fluids.

Danger
Risk of burning from hot functional fluids and hot surfaces.
Allow hot functional fluids and hot surfaces to cool first.
Wear your personal protective equipment. Cover hot surfaces
with heatĆresistant materials.

BP09_020_1108EN 5ĂĊĂ5

Maintenance

Danger
Risk of injury from pressurised hydraulic fluid. Put the machine out
of service before starting maintenance, inspection and repair work.
Depressurise the hydraulic system. Dump pressure from the accuĆ
mulator.

Danger
Risk of injury from compressed air. Put the machine out of service
before starting maintenance, inspection and repair work.
Depressurise the compressed air system.

Danger
Risk of injury from whipping hydraulic hoses. Mechanically preĆ
stressed hydraulic hoses may lash out when loosening the threaded
union. Wear your personal protective equipment. Secure the
hydraulic hoses tightly in place when loosening the threaded unions.

Danger
Risk of injury from the machine starting unexpectedly. Before starting
maintenance, inspection and repair work, put the machine out of
service and secure it against unexpected restarting (e.g. remove
ignition key and put it in your pocket, place a warning plate on the
controls). If this is not possible, ask someone to stand guard who
can prevent the machine from starting up unexpectedly.

5ĂĊĂ6 BP09_020_1108EN

Maintenance

5.3 General tightening Tightening torques depend on:
torques − bolt grade
− thread friction
− bolt head bearing area

The values given in the following tables are for guidance. These vaĆ
lues should only be used if no other values are specified in the relĆ
evant chapters of the Operating Instructions or in spare parts sheets.

Caution
You must always use bolts of the same size and property class when
you have to replace bolts. Bolts with adhesive in the locking threads
and selfĆlocking nuts must always be replaced after removal.

5.3.1 Set screws and nuts You will find the maximum tightening torques for set screws and nuts
in spare parts list.

Note
For threaded unions, tighten the union nut using a spanner. While
doing so, you must use another spanner to hold the threaded conĆ
nection in place.

10400100

Tighten threaded union

BP09_022_1309EN 5ĂĊĂ7

Maintenance

5.3.2 Flared screwed joint, Every time the joint has been undone, the union nut must be tighĆ
reassembly tened again securely without excessive force.

Flared screwed joints

External MA [Nm] External MA [Nm]
diameter (RAD)/
diameter (RAD)/ Type 130
120
Type 250
400
6L 20 16 S 500
8L 40 18 L 800
10 L 45 20 S
55 25 S
L 80 30 S
12 70 38 S

S
15 L

* RAD = pipe external diameter
* MA = tightening torque

" Tighten the union nut using a spanner. While doing so, you
must use another spanner to hold the threaded connection in
place.

5.3.3 Profiled ring joint, After each time the joint is undone, the union nut must be tightened
reassembly again securely without excessive force to ensure that the joint is
tight.

5ĂĊĂ8 BP09_022_1309EN

Maintenance

5.3.4 WALFORMplus Below you will find an overview of the most important components in
threaded union the WALFORMplus threaded union. The next section describes what
must be borne in mind during reassembly of WALFORMplus
threaded unions.

12

4 3

BP09_022_1309EN 6

No. 0 Designation

1 Threaded connection
2 Union nut
3 Pipe
4 Seal

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Maintenance

5.3.5 WALFORMplus For reassembly of the WALFORMplus threaded union, proceed as
threaded union, follows:
reassembly
" Check the thread for cleanliness and damage.
" Clean the thread, and if necessary, replace the parts with a

damaged thread.
" Each time the connection is loosened, check the gasket for

damage, and replace it if necessary.
" For threaded unions made of rustĆproof steel, grease the

thread and the reshaped area of the pipes with an adequate
amount of EATONĆABF grease.
" Pull the gasket onto the reshaped pipe as far as the stop.

Note
Firmly tighten the union nut again using the same torque as for initial
installation.

" Tighten the union nut using a spanner. While doing so, you
must use another spanner to hold the threaded connection in
place.

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Maintenance

Note
The tightening torques are guide values, and only apply to optimum
conditions. The torques may deviate substantially because of tolerĆ
ance influences, pipes fitted under tension and incorrect lubrication.

Tightening torques

WALFORMplus threaded unions

External MA [Nm] External MA [Nm]

diameter (RAD)/ diameter (RAD)/ 110
140
Type Type 210
300
6 L 30 18 L 400

8 L 35 22 L

10 L 40 28 L

12 L 55 35 L

15 L 80 42 L

* RAD = pipe external diameter
* MA = tightening torque

Tightening torques

WALFORMplus threaded unions

External MA [Nm] External MA [Nm]

diameter (RAD)/ diameter (RAD)/ 150
210
Type Type 280
410
6S 35 20 S
8S 40 25 S
10 S 55 30 S
12 S 70 38 S
16 S 110

* RAD = pipe external diameter
* MA = tightening torque

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Maintenance

5.4 Functional fluids This section lists all the functional fluids used in your machine.
5.4.1 Hydraulic fluid
Caution
Never use hydraulic fluids or lubricants with additives such as
molybdenum. Such additives can attack the bearings.

The hydraulic system is filled with:
− mineral hydraulic fluid (HLP) or
− biologically degradable hydraulic fluid based on a synthetic ester

(HEES) or
− non−readily flammable hydraulic fluid (HFC).

Please see the machine card to find out what the initial filling was in
your machine.

Danger
Never mix hydraulic fluids of different types, i.e. do not mix biologiĆ
cally degradable hydraulic fluids with mineral hydraulic fluids etc.

The hydraulic fluid reservoir has a capacity of 215 litres up to the
min" mark and a capacity of 235 litres up to the max" mark. The
machine must be standing level, the boom must be folded, and the
supports must be retracted when the hydraulic fluid level is being
checked.

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Maintenance

Note
Please only use a hydraulic fluid complying with the classification
and requirements standards specified in the lubricant recommendaĆ
tion for topping up or a full fluid change. HEES synthetic esters and
HFC aqueous solutions from different manufacturers must not be
mixed together without prior approval from the manufacturers
concerned.

When hydraulic fluids of different viscosity grades are mixed, the
new viscosity is determined by the mix ratio. Loss of quality is
possible if hydraulic fluids from different manufacturers are mixed.
For this reason, you must always consult the manufacturer before
mixing fluids.

When the hydraulic fluid is changed, some 10Ă−Ă15% of the old hyĆ
draulic fluid remains in the system (in cylinders, pumps, lines, etc).

Take note of VDMA’s changeover guidelines and manufacturer’s
instructions if you are changing over your fluid. Please contact the
manufacturers concerned if you have any queries regarding the
suitability and miscibility of hydraulic fluids.

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Maintenance

5.4.2 Level of contaminant Level of contaminant 19/16/12 in accordance with ISO 4406 is speciĆ
fied for lubrication and the hydraulic system. You can find the level of
contaminant of the initial filling from the test report on the machine
card.

5.4.3 Lubricant analysis We can carry out a lubricant analysis for you should you discover
that the functioning of your machine is impaired with one of the
lubricants or hydraulic fluids used. Please consult Putzmeister,
Department APS (After Sales) and request our analysis kit
(material no. 257260.004). We will carry out a lubricant analysis
to determine the cause.

5.4.4 Storage of lubricants Do not store oils and greases in the open air. Water may be
absorbed through the bung hole in the event of changes in the
exposure to the weather.

Only ever store the barrels lying on their side and supported on
timber blocks, with the bung hole facing upwards.

Environmental protection
You must carefully collect all functional fluids, e.g. used oil (including
biologically degradable oils), filters and auxiliary materials and disĆ
pose of them separately from other waste. You must keep used oils
of various types separate in order to keep disposal costs as low as
possible.

Observe the national and regional regulations applicable to your
area. Only work with waste disposal companies who are approved
by the responsible authorities.

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Maintenance

5.5 Lubricant You will find suitable lubricants and hydraulic fluids in the tables
recommendation below. Putzmeister accepts no liability for the quality of the lubricants
and hydraulic fluids listed or for changes in quality made by the
lubricant manufacturer without changing the grade designation.

Note
Please use only Putzmeister hydraulic fluid, material no. 239879002,
when you are topping up the hydraulic fluid or carrying out a full fluid
change if your machine was filled with non−readily flammable hyĆ
draulic fluid in the works (HFC as specified in the 7th Luxembourg
Report).

Please use only Putzmeister hydraulic fluid, material no. 239693000,
when you are topping up the hydraulic fluid or carrying out a full fluid
change if your machine was filled with a synthetic ester in the works.

Putzmeister accepts no liability for damages caused by mixing fluids
from different manufacturers.

You must first consult Putzmeister Department APS if you wish to use
hydraulic fluids with viscosity grades other than VG46 (e.g. at higher
ambient temperatures).

The proportion of residual fluid must not be greater than 2% after a
fluid change from HLP to HEES. This means that a flushing filling with
the full quantity of the new hydraulic fluid must be carried out. In
addition, for reasons of gasket compatibility, a fluid change must
be carried out no later than 6Ămonths after the machine is commisĆ
sioned. It should also be noted, at this point, that all filters must
be changed after 50 hours of operation, since deposits may be
dissolved and transported to the filters by the new fluid.

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Maintenance

Caution
The following points must be complied with in order to prevent
damage:
ć You must warm the machine up briefly if you wish to start using it

when the hydraulic fluid temperature is below 0Ă_C. To do this,
engage the power take−off, switch off the concrete pump and
allow the machine to idle for a few minutes.
ć The machine should not be placed under full load until the temĆ
perature of the hydraulic fluid (VG46) has risen above 10Ă_C.
ć The ideal temperature for the hydraulic fluid (HLP or HEES, VG46)
is between 40Ă_C and 70Ă_C.

Danger
Never mix hydraulic fluids of different types, i.e. do not mix biologiĆ
cally degradable hydraulic fluids with mineral hydraulic fluids etc.

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Maintenance

5.5.1 Oils

Requirements Rotor gearbox Agitator Slewing gear Transfer
standard gearbox transmission gearbox
Characteristics DIN 51 517 DIN 51 517 DIN 51 517
synthetic mineral see spare parts
Viscosity grade, CLP 220 CLP 220 mineral sheet
NLGI Class 000101.006 CLP 220
Material no. 295246.006 000101.006

Note
Truck transmissions, truck engines and independent power units are
filled by the respective manufacturer. Maintenance only in accordĆ
ance with the manufacturer’s specifications.

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Maintenance

5.5.2 Greases Greasing Centralized Greasing the pump
(manual) lubrication system tube in rotor pumps
Marking in
accordance K2K−30 K1K−30 Ċ
with DIN 51 502
Requirements DIN 51 825 DIN 51 825 Ċ
standard Ċ
Characteristics mineral, lithium soap Ċ
Viscosity grade, 290207.008
NLGI Class NLGI Class 2 NLGI Class 1
Material no. DIN 51818 DIN 51818

360000.009 360001.008

Note
We recommend the following grease, rather than those specified in
the lubricant table, should you wish to fill the centralized lubrication
system with a low temperature grease in extremely cold conditions:
Marking in accordance with DINĂ51502: KĂEĂ2G−60, NLGI ClassĂ2

5ĂĊĂ18 BP09_016_0708EN