Manual safety regulation_EN

Safety regulations

2.11 Mobile machines It is the machine operator who takes responsibility for setting up the
2.11.1 Set-up site machine safely. He must inspect the proposed set−up site and must
refuse to set the machine up at the site of operations if he has any
doubts regarding safety.

As machine operator, you must familiarise yourself with the working
area and surroundings before work is begun. The working area and
surroundings include, in particular, obstacles in the work and travelĆ
ling areas, the loadbearing capacity of the supporting ground and
any barriers separating the construction site from public roads.

The setĆup site must have sufficient lighting to ensure safe operation
of the machine. Ensure that the setĆup site is adequately lit.

Do not park the machine in areas where equipment may fall down.

Incidents of overlapping with the working areas of other machines
(particularly cranes, other placing booms, etc.) should be avoided
as far as possible. If this is not possible, special care and attention is
required when setting up and operating machinery. If necessary, you
must use a signaller.

You must also check the approach route to the site where the maĆ
chine will be set up. If you are unsure whether the approach route is
suitable, prepare the route before work is started. It is especially
necessary to walk the approach route once in darkness and at dusk
or dawn. You should repeat this exercise again before leaving the
construction site.

You must always ask for a signaller if you have to reverse. If necessĆ
ary, have the approach route closed off or secured by signallers.
Have any materials or equipment that hinder your approach reĆ
moved.

BP03_082_1501EN 2ĂĊĂ27

Safety regulations

2.11.2 Supporting ground Check the loadbearing capacity of the supporting ground. The site
management will be able to state the permitted ground pressure.

wz0087

The supporting ground must be level and even. If necessary, set up
a level surface on top of the uneven ground. There must be no voids
or other ground irregularities under the support feet. Asphalt, conĆ
crete slabs, etc. may have been washed out underneath. Never set
the machine up on backfilled ground.

The support area must be enlarged as required. Support blocks and
timber blocks may be used to increase the support area. The supĆ
port timbers must be undamaged and free from ice, oil, grease, etc.
The support blocks and timber blocks must be laid under the supĆ
port plates such that the load is distributed uniformly and the supĆ
port leg cannot slip off the side of the support.

Check the stability of the machine regularly during operation. InterĆ
rupt the pumping operation if the machine becomes unstable. FacĆ
tors which reduce stability include, for instance:
− Modifications to the ground conditions, particularly caused by rain

water or the thawing of frozen ground
− the support sinking on one side
− fluid losses through leaks in the support hydraulics

2ĂĊĂ28 BP03_082_1501EN

Safety regulations

2.11.3 Corner bearing loads The corner bearing load is stated on each support leg. This value
must always be legible.

wz0095

The force transferred to the ground by each support leg diffuses
through the soil in a conical pattern at an angle of 45_. Safe clearĆ
ance to the pits and slopes must be maintained, and such clearance
must be determined in accordance with the nature of the ground.
The safe clearance is measured from the foot of the pit.
However, for undisturbed, compacted ground, the safe clearance
corresponds to pit depth, but must be a minimum of 2 m.
For loose or back−filled ground, the safe clearance is twice the pit
depth, but a minimum of 2 m.

BP03_082_1501EN 2ĂĊĂ29

Safety regulations

2.11.4 Supports The placing boom must not be raised until the machine has been
supported in accordance with the Operating Instructions. There is
otherwise a risk of the machine toppling over.

Swing out and telescope the support legs to their end positions in
sequence. Intermediate positions are prohibited to guarantee stabilĆ
ity. Exceptions are machines which have been equipped by the
manufacturer with a device which allows secure erection with a reĆ
duction in support. Check the corresponding notes in this regard in
the operating instructions.

Do not carry out more than one movement at a time. If a movement is
stopped, the entire volume of fluid is available for the remaining
movements, and can increase their speeds. Depending on the deĆ
sign, it may be the case that carrying out several movements at once
(as opposed to carrying out a single movement at maximum speed
at any one time) does not bring any advantage in terms of time.
Carrying out several movements at once requires an increased level
of attentiveness.

Lock all supports mechanically, if this is provided for in the design.
Close all shutĆoff valves in the support hydraulics. Leaks can cause
the supports to sink on one side.

2ĂĊĂ30 BP03_082_1501EN

Safety regulations

The machine must be made level in all directions. Provided the
manufacturer does not state otherwise, the maximum permissible
deviation from the horizontal is 3_. Greater deviations from the horiĆ
zontal overload the slewing gear for the placing boom as well as its
overall support structure, jeopardising the stability of the machine.

wz0106

Check stability regularly during operation. The elastic distortions to
the machine frame occasionally occurring under extreme positions
of the placing boom (one support foot lifts from the ground) must be
compensated for by resetting the support cylinders until all support
feet are firmly placed on the ground.

BP03_082_1501EN 2ĂĊĂ31

Safety regulations

2.11.5 Driving When preparing the machine for driving, you must perform the folĆ
lowing tasks in particular:
− The placing boom must be folded in fully and positioned on the

placing boom support provided.
− The support legs and support feet must be fully retracted and seĆ

cured.
− Raised or locked axles must be lowered and released.
− Accessories and moving parts belonging to the machine must be

safely stowed/secured.
− The maximum permissible gross weight may not be exceeded.

While the vehicle is being driven, the delivery line, pump and hopper
must be empty. If there are concrete leavings in the hopper, it must
not be possible for the leavings to be thrown out while the vehicle is
in motion, thereby creating a risk of injury. You must adapt your drivĆ
ing style to the altered centre of gravity of the machine. Observe the
road traffic regulations and specifications of the machine manufacĆ
turer.

Maintain a clearance of at least 1 m from the secured edges of conĆ
struction pits and at least 2 m from slopes.

wz0166

2ĂĊĂ32 BP03_082_1501EN

2.11.6 Towing Safety regulations

Always make sure that there is sufficient clearance when driving
under underpasses, over bridges and through tunnels or when pasĆ
sing under overhead cables. The same minimum clearances apply
when driving under high−voltage lines as when working with the
placing boom. Be aware of the height of the truck. Only drive over
arches, bridges or other supporting structures if the loadbearing caĆ
pacity is adequate.

Do not drive across uphill or downhill gradients. Be aware of the elĆ
evated position of the truck’s centre of gravity when travelling on a
slope and on ascending or descending routes. Always adapt your
travelling speed to the prevailing conditions on sloping terrain. Never
change to a lower gear on a slope but always before reaching it.

Observe national road traffic regulations. If necessary, clean the
tyres, lights and number plate. Before travelling with the machine,
check that the braking, steering, signalling and lighting systems are
fully functional.

Persons accompanying the driver must be seated on the passenger
seats provided for this purpose.

Whilst the truck is in motion, the mixer drum on truck mixer concrete
pumps must only be rotated at the maximum speed of rotation speciĆ
fied in the Operating Instructions. The truck is at risk of tipping over,
particularly when travelling round corners.

The machine must only be towed, loaded and transported in accordĆ
ance with the Operating Instructions. Only use existing towing
hitches for towing and observe the truck manufacturer’s regulations.

You must comply with the prescribed driving position, permitted
speed and itinerary when towing.

BP03_082_1501EN 2ĂĊĂ33

Safety regulations

2.11.7 Loading The lifting points fitted to the machine as standard are provided for
assembly purposes only. They are not suitable for lifting the comĆ
plete machine. The lifting points for lifting the entire machine are
specially marked.

wz0176

Use only appropriate means of transport and lifting equipment of adĆ
equate loadbearing capacity. Lifting equipment, lifting tackle, supĆ
port trestles and other auxiliary equipment must be reliable and safe
in operation.

Use only stable loading ramps of adequate loadbearing capacity for
loading. Ensure that no−one is at risk from the machine tipping over
or slipping.

Secure the machine against rolling, slipping and toppling over on the
transport vehicle.

2ĂĊĂ34 BP03_082_1501EN

Safety regulations

2.12 Placing booms

2.12.1 Unfolding the placing Only raise a mobile placing boom from the driving position once the
boom machine has been supported in accordance with the Operating InĆ
structions. Stationary booms may only be raised after the proper
set−up has been checked by a subject expert.

Only raise the placing boom in the sequence described in the OperĆ
ating Instructions. The correct sequence depends on the folding sysĆ
tem (roll−and−fold system, Z−fold system, etc.).

Do not carry out more than one movement at a time. If a movement is
stopped, the entire volume of fluid is available for the remaining
movements, and can increase their speeds. Depending on the deĆ
sign, it may be the case that carrying out several movements at once
(as opposed to carrying out a single movement at maximum speed
at any one time) does not bring any advantage in terms of time.
Carrying out several movements at once requires an increased level
of attentiveness.

The range of a radio remote control is great enough for the machine
to receive control commands (e.g. from a great distance, from inside
enclosed spaces), even without visual contact. If there is no visual
contact, for example, because you are changing workplace, you
must switch off the remote control. If there is no visual contact, for
example, because the construction site is unclear, signallers MUST
be used, and must remain in contact with the machine operator
using suitable means, and have visual contact with the site of conĆ
crete placement, work areas and danger zones, and the machine.

Always ask the site management to provide you with an assistant to
act as a signaller. Agree clear hand signals or other signals with the
signaller so that you can communicate with each other. You should
position the signaller such that he can always observe the whole of
the placing boom. Your primary duty as the machine operator is to
observe the site of concrete placement.

BP03_082_1501EN 2ĂĊĂ35

Safety regulations

Only slew the placing boom over persons when the delivery line and
end hose are empty. There is a risk of concrete falling out of the end
hose.

Press the EMERGENCY STOP button immediately if the placing
boom moves unexpectedly. If this should occur, you must cease
working and have the cause of the fault rectified by your qualified
personnel or our After Sales Department.

wz0056

Placing booms with placing boom hinges which allow considerable
flex angles have a very large potential working area. This high maĆ
noeuvrability means different placing booms can also be moved into
dangerous positions. Prohibited areas can be found in the Operating
Instructions.

There is a risk that you will damage the truck, truck superstructure or
obstacles on the construction site with the placing boom. Under cerĆ
tain circumstances it is even possible to overload or cause damage
to the placing boom. Uncontrolled movements may result from the
sudden, violent release of the placing boom after collisions. This may
also result in (possibly fatal) personal injury.

The manufacturer has indicated such impermissible working areas
by the use of warning signs and information plates on the machine
and appropriate notes in the Operating Instructions.

2ĂĊĂ36 BP03_082_1501EN

Safety regulations

2.12.2 Guiding the end hose The end hose must hang freely each time you start pumping, when
you start pumping again after blockages, and during washing out
procedures. NoĆone should stand within the danger zone of the end
hose. The diameter of the danger zone is twice the end hose length.
Do not guide the end hose when pumping is started. There is a risk
of injury from the end hose swinging out or stones being ejected.

wz0136

If a longer end hose is used, the diameter of the danger zone is also
increased (see also page 2ĂĊĂ12).

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

There is a risk of injury to the hoseman if the end hose becomes
caught in the reinforcement and suddenly jumps out on further
movement of the placing boom.

BP03_082_1501EN 2ĂĊĂ37

Safety regulations

Never bend the end hose over. Never attempt to straighten a bent
end hose by increasing the pressure. The end hose must not be subĆ
merged below the surface of the concrete being delivered, otherwise
the concrete may spray upwards.

The concrete may also spray from the end hose due to the presence
of air in the delivery line. To prevent this from occurring, the hopper
must be filled with concrete at least as far as the agitator shaft so
that no air can be sucked in.

The end hose must be secured against falling.

2.12.3 Guiding the end hose The hoseman must guide the end hose in such a way that prevents
ergonomically excess spraying of concrete, and so that concrete is directed preĆ
cisely into the site of concrete placement.

Control the placing boom so that the hoseman can guide the end
hose without power consumption. The hoseman must not carry the
end hose by hand, because the weight of it may cause permanent
personal injury.

2ĂĊĂ38 BP03_082_1501EN

Safety regulations

2.12.4 Procedure in storms Return the placing boom to the driving position in the event of storms
or bad weather.
− Placing booms with a vertical reach of 42Ăm or more may only

be operated in wind forces up to 7 Ă
(wind speed 51 km/h = 14 m/s).
− Placing booms with a vertical reach of less than 42Ăm may only
be operated in wind forces up toĂ8
(wind speed 74 km/h = 20 m/s).

Wind speeds in accordance with the Beaufort scale are average
wind speeds measured over a period of 10 minutes. Higher speed
gusts of wind may occur briefly during the measuring period.
Higher wind speeds jeopardize stability and safety of the structural
elements. There is a risk of lightning strike in a thunderstorm.

A lightning strike poses a lethal danger to persons. The machine and
the surrounding area will be charged with electricity. Earthing the
machine does not reduce this risk. For this reason, you should fold in
the placing boom if there is a risk of lightning strike.

2.12.5 Concreting in cold Tower cranes on construction sites generally have wind speed
weather measuring equipment, so that you can ask about the wind speed at
any time. If no wind speed measuring equipment is available, you
can ask the nearest meteorological office what the wind speed is, or
estimate the wind speed using the following rule of thumb.
− In winds of forceĂ7 and greater, green leaves break from the trees

and there is perceptible resistance when walking against the wind.
− In winds of forceĂ8 and greater, small branches break from trees

and walking outside is significantly impeded.

The boom must not be used in temperatures below minus 15Ă_C
(+Ă5Ă_F) unless the manufacturer has given express approval. There
is a danger of damage to the steel (brittle fracture) and the seals
throughout the system at such extreme minus temperatures.

In addition, such minus temperatures should be considered the realĆ
istic lower limit for concrete placement, as it is no longer possible to
prepare concrete such that it can achieve its strength without the use
of special additives.

BP03_082_1501EN 2ĂĊĂ39

Safety regulations

2.13 Delivery line systems

2.13.1 Suitable delivery lines Use only delivery lines, end hoses, couplings, etc. which are in perĆ
fect condition and suitable for the delivery job, and have been apĆ
proved by the machine manufacturer. Delivery lines are subject to
wear which varies according to the pressure and composition of the
concrete, the material from which the delivery line is made, etc.

2.13.2 Securing delivery Delivery lines, delivery hoses, end hoses and couplings must be seĆ
lines curely fastened and secured against spontaneous opening.

wz0066

2ĂĊĂ40 BP03_082_1501EN

Safety regulations

2.13.3 Tightness and Regularly force water through the delivery line under operating presĆ
blockages sure to check that the system is watertight.

wz0047

A properly−cleaned delivery line is the best insurance against the
formation of blockages. Blockages increase the risk of accidents.
Never attempt to push through a blockage (e.g. by increasing the
delivery pressure, using compressed air, etc.). There is a risk of fatal
injury from the delivery line bursting or from concrete being ejected
from the end of the delivery line.

Prevent blockages by adjusting the operating conditions. Remove
blockages by reverse pumping and then restarting forward pumping.
Repeat this process several times if necessary. If the blockage is not
removed, relieve the pressure on the delivery line before removing
the section of delivery line concerned.

BP03_082_1501EN 2ĂĊĂ41

Safety regulations

2.13.4 Opening delivery lines You must not open or tap delivery lines while these are pressurized.
Concrete exiting under pressure can cause injury. The concrete colĆ
umn must be depressurized by reverse pumping before the delivery
line is opened. Never work bending directly over the coupling.

wz0076

2.13.5 Clearance to delivery No−one should remain in the vicinity of separate delivery lines during
lines pumping operations. Cordon off the danger zone. If it is not possible
to place a large enough cordon around the danger zone, the delivĆ
ery line must be covered by suitable means.

2.13.6 Fastening delivery Delivery lines, in particular riser lines which are not laid along placĆ
lines ing booms, must be securely fastened in order to transfer the forces
generated in them into the structure or other structural members. The
lines must be laid so as to avoid kinks, sharp bends, stresses and
damage during pumping operations.

2ĂĊĂ42 BP03_082_1501EN

Safety regulations

2.13.7 Continuation delivery If a continuation delivery line is connected to the placing boom, it

lines must not place any further strain on the placing boom.

While you connect, use and disconnect a continuation delivery line,
you must switch off the arm assembly control system to prevent uninĆ
tended movements of the arm assembly. There is a risk of accident
posed by jerky movements of the boom tip.

2.13.8 Devices for shutting– During operation there is a risk of being crushed and of injury by
off, diverting or clean- shearing. Hydraulically driven devices are generally supplied with
ing delivery lines power by a machine’s hydraulic system. It must therefore be possĆ
ible to see from the devices and the machine with control unit and
vice versa. Observe the Safety Manual for the machine and the deĆ
vice when connecting and operating a device. Make sure that no−
one is in the danger zone before operating devices.

Use only suitable, perfectly functioning devices to shut−off, divert
and clean the delivery line. Defective and unsuitable devices may
cause damage to the whole delivery system and injure persons in
the surrounding area due to a malfunction.

BP03_082_1501EN 2ĂĊĂ43

Safety regulations

2.14 Pumping operations The machine operator’s place of work is with the remote control when
2.14.1 Place of work the pump is in operation. If you operate the machine using the reĆ
mote control, all operating and control devices on the machine must
be closed to prevent unauthorized interventions.

In the case of stationary placing booms, platforms or similar equipĆ
ment are only provided for assembly and maintenance work. Use of
these platforms as a workplace during operation is prohibited.

2.14.2 Safety It is forbidden to climb onto the machine during operation. In the
case of stationary placing booms, it is forbidden to climb ladders
during operation.

Before switching on or restarting the machine or individual machine
functions, you must ensure that doing so will not endanger anyone’s
safety.

2.14.3 Remote control Refrain from any procedures that may impair the stability of the maĆ
chine or are prejudicial to safety in any other way.

You must always carry the remote control on your person when the
machine is ready for operation. Only in this way can it be guaranteed
that you can press the EMERGENCY STOP button in the event of an
emergency situation. The EMERGENCY STOP button may only be
unlocked once the cause/emergency has been remedied.

As a general rule, you must carry the remote control so that no conĆ
trol elements are activated unintentionally. If your attention is drawn
away from the machine (particularly when changing workplace), you
must switch off the remote control.

During breaks in pumping, interruptions, maintenance work, or beĆ
fore you leave the machine, you must secure it against unintended
movements and unauthorized use. Switch off the remote control and
lock it away.

2ĂĊĂ44 BP03_082_1501EN

Safety regulations

2.14.4 Moving machine com- Keep all access covers, maintenance flaps, guards, etc. closed and
ponents and hot sur- locked during operation. This also applies in particular to the grille,
faces water box cover and covers over cylinders. There is otherwise a risk
of injury from moving parts of the machine and a risk of burning on
hot surfaces. In particular, there is a risk of burns from the engine,
attached parts and the exhaust.

Never start work unless the grille is closed and bolted down or otherĆ
wise secured.

Do not touch moving parts of the machine, whether the machine is
running or switched off. Always switch off the engine first, and dump
the accumulator pressure where an accumulator is fitted.

Never poke any objects (e.g. a shovel handle, trowel or similar) into
moving machine components. Such objects could become trapped
and dragged into the machine. They might then hit you or be torn
from your hands and cause you injury.

2.14.5 Constant observation You should be constantly observing the machine for any damage or
of the machine faults while it is in use. In the event of faults or malfunctions that imĆ
pair safety at work, shut the machine down immediately and secure
it. Have the faults rectified immediately. If it is not possible to rectify
faults which jeopardize the safe operation of the machine, you must
suspend operations until the defects are rectified.

2.14.6 Truck mixer As the machine operator, it is your role to instruct the truck mixer
drivers who deliver the concrete to you, so that they are able to operĆ
ate the operating elements on the concrete pump provided for their
use. Only allow the truck mixer drivers to work alone once you are
certain that they have understood your instructions.

Make sure that no−one stands between the approaching truck mixer
and the machine. There is a danger of being crushed between the
truck mixer and the machine.

BP03_082_1501EN 2ĂĊĂ45

Safety regulations

2.15 Cleaning You must drain the delivery line, pump and hopper completely. ConĆ
2.15.1 General crete leavings in the hopper, in particular, may be thrown out whilst
the truck is moving.

The machine must not be driven with the placing boom unfolded or
the support legs extended, even over short distances. This rule also
applies when you have to drive the machine to a different site for
cleaning. The placing boom and support legs must be fully retracted
and secured.

wz0156

The preferred methods for cleaning the delivery line are reverse
pumping or forced cleaning with water. The agitator must be
switched on during reverse pumping. Otherwise, the concrete flowĆ
ing back into the hopper can bend the agitator shaft. Use a catch
basket, pipe cleaning head and wash−out ball for forced cleaning to
prevent any water from flowing into the formwork.

Never spray remote controls or control cabinets with barrier agents
(mould oil or similar) to protect them against contamination. This
causes significant corrosion damage to the electrical system.

2ĂĊĂ46 BP03_082_1501EN

Safety regulations

2.15.2 Cleaning agents There is a risk of injury at all points on the machine from slipping,
tripping, bumping into things, etc. Use the handles and steps to
climb into and out of the machine. It is forbidden to stand on the
grille. Do not jump from the machine.

Do not reach into the hopper or any other moving machine compoĆ
nents. This rule must also be followed when you are opening the
outlet on the bottom of the hopper. Do not remove the grille.

Only point the water jet into the hopper or other moving machine
components. Do not insert the hose. It could become entangled with
moving machine components.

Take care when using aggressive cleaning agents. Aggressive
cleaning agents may attack materials (e.g. rubber) and painted surĆ
faces. You can use commercially available paint cleaning and care
agents, as long as these have a pH value of between 4 and 9. Ask
the manufacturer of the cleaning agent to confirm its suitability. ObĆ
serve the manufacturer’s instructions regarding use and safe handlĆ
ing. Wear protective clothing. Always rinse off cleaning agent thorĆ
oughly with clean water; do not allow puddles to form.

wz0146

Do not use sea water or other water containing salt for cleaning purĆ
poses.

Do not use any highly flammable agent for cleaning; there is a
danger of fire.

BP03_082_1501EN 2ĂĊĂ47

Safety regulations

2.15.3 Cleaning with com- When the delivery line is being cleaned with compressed air, there is
pressed air an increased risk of accident from explosively escaping compressed
air, spurting concrete and flapping delivery or end hoses if they have
not been removed.

Compressed air should only be used for cleaning purposes under
the supervision of a subject expert. All persons participating in the
cleaning procedure must be instructed in the Safety Manual.

The manufacturer accepts no liability for damage caused by incorĆ
rectly performed compressed air cleaning. If you blow out the delivĆ
ery line with compressed air, you must observe the following rules
without fail:
− Individual pipes and short pipe runs up to 10Ăm in length must not

be blown through with compressed air. There is a risk of accident
from rebound.
− Only blow out delivery lines which have the same nominal diamĆ
eter throughout their length. Reducer pipes must be drained and
flushed out by hand.
− No bends, delivery or end hoses may be fitted at the end of the
delivery line.
− A catch basket must be fastened at the end of the delivery line
and a wash−out adaptor must be fitted on the head of the delivery
line. Catch basket and wash−out adaptor must fit the delivery line
system.
− The concrete must be able to flow freely from the end of the delivĆ
ery line.
− No persons may be present in an area of 3Ăm around the delivery
line, at the end of the delivery line and especially in front of the
opening in the catch basket.
− Care must be taken to ensure that any concrete that might be exĆ
pelled from the catch basket cannot injure anybody or cause any
damage.

2ĂĊĂ48 BP03_082_1501EN

Safety regulations

2.15.4 Protection against − The wash−out adaptor must be fitted with a separate, large dump
water cock and a pressure gauge.

2.15.5 Post–cleaning − The pressure gauge must be kept under constant observation durĆ
procedure ing the cleaning process. The pressure in the delivery line must be
rapidly dumped via the dump cock in the event of a sudden drop
in pressure (concrete column exiting from the end of the line) or
increase in pressure (risk of blockage).

− The sponge ball or the plug used to push the concrete out must
be sufficiently dense that the air does not pass through it into the
concrete. In addition, the delivery line must be sealed to the rear
when the sponge ball or plug is caught in the catch basket.

− Only work on the delivery line (particularly when opening the delivĆ
ery line) if it has been depressurized. Make sure that the comĆ
pressed air has been dumped completely.

− The dump cock must be opened in such a way that no−one can
be injured by concrete residue that might be expelled from the
dump cock.

Water spraying on the machine from random directions has no damĆ
aging effect. The electrical system is protected against spray water,
but is not waterproof.

You must close/seal all openings into which water/steam/cleaning
agent must not penetrate for safety or functional reasons before
cleaning the machine with water or a steam jet (high−pressure
cleaner) or other cleaning agents. Electric motors and control cabiĆ
nets are particularly at risk.

After the machine is cleaned, the covers/tapes must be completely
removed and the machine must be checked to ensure that it is ready
for operation (see also page 2ĂĊĂ20).

Look out for leaks, loose connections, chafe marks and damage durĆ
ing the cleaning procedure. Any identified defects must be rectified
immediately. The machine must be greased after it has been
cleaned using a high−pressure cleaner.

BP03_082_1501EN 2ĂĊĂ49



3 General technical description

This chapter describes the components and assemblies on this
machine and describes how they function. Please note that available
options will also be described. The machine card will tell you
whether the option described is fitted to your machine.

BP02_001_0302EN



General technical description

3.1 Overview Below you will find an overview of the most important components;
Left truck side these will then be described on the following pages.

ÁÁ1 2 34 56 78 9 10 11 12

No. 0 Component BP23_121_1210EN 1

1 Documentation accompanying the machine Page

Radio and/or cable remote control 3ĂĊĂ70
2 3ĂĊĂ77
3ĂĊĂ130
Ergonic Graphic Display − Remote Control (EGDĆRC)
3ĂĊĂ22
3 Boom functions emergency control levers (in the stowage compartĆ 3ĂĊĂ126
ment) 3ĂĊĂ115
3ĂĊĂ145
4 OSS flashing beacon 3ĂĊĂ131
3ĂĊĂ131
5 Left support control block 3ĂĊĂ148
3ĂĊĂ15
6 Spotlights for lighting the support area 3ĂĊĂ123
3ĂĊĂ134
7 Flushing water pump (on the water tank)

Accumulator dump valve
8

Agitator and water pump control block

9 Vibrator (on the grille)

10 Transfer tube

11 Agitator safety cutout

12 End hose (on the boom tip)

BP23_121_1210EN 3ĂĊĂ1

General technical description

Right truck side

12 3 4 5 6 78 9 10 11 12

BP23_121_1210EN 2

No. 0 Component Page

1 Mushroom−head button for horn on the boom (on the side of the 3ĂĊĂ152
hopper) 3ĂĊĂ68
3ĂĊĂ131
2 Manual throttle lever 3ĂĊĂ131
3 Control panel (in the steps) 3ĂĊĂ119
3ĂĊĂ149
Pump control system 3ĂĊĂ115
4 3ĂĊĂ126
3ĂĊĂ20
Transfer tube damping 3ĂĊĂ23
5 Magnetic switches distributor casing
6 Hydraulic fluid radiator 3ĂĊĂ22
7 Spotlights for lighting the support area 3ĂĊĂ8
8 Right support control block 3ĂĊĂ9

Control cabinet (in the stowage compartment)
9 Ergonic Graphic Display (EGD)

EPS computer (Ergonic Pump System)
10 OSS flashing beacon
11 Machine rating plate
12 Boom rating plate

3ĂĊĂ2 BP23_121_1210EN

General technical description

3.2 Safety equipment This illustration shows examples of safety equipment which may be
fitted on the machine. The mounting location may differ on different
machine models (e.g. other side of the truck).

1 2 34 5 62 7

BP21_611_0904EN 1

No. 0 Safety equipment

1 EMERGENCY STOP button / STOP button on the remote control
2 Snaplock on the support leg
3 Retaining rope on the end hose

EMERGENCY STOP button
4

Two−hand control device for the support legs
5 Water box cover

Ventilation of air−sprung axles
6

Locking of lifting axles
7 Cover over the switch cylinders

BP21_611_0904EN 3ĂĊĂ3

General technical description

1

2
3

BP21_611_0904EN 2

No. 0 Safety equipment
1 Securing cotter pins on the delivery line couplings
2 Spray guard
3 Grille on the hopper

3ĂĊĂ4 BP21_611_0904EN

General technical description

1 23 4 5 6 74

BP21_611_0904EN3

No. 0 Safety equipment

1 Agitator safety cutout
2 Mechanical grille securing device
3 Cover over the switch cylinders
4 Snaplock on the support leg

EMERGENCY STOP button
5

Two−hand control device for the support legs
Toggle switch for Local control − 0 − Remote control
6
OSS equipment
7 Cover over the boom functions control block

Danger
Never operate the machine if the safety equipment is not working.
You could injure yourself or others or damage the machine.

Check the safety equipment as described in the Operating Instructions.

BP21_611_0904EN 3ĂĊĂ5

General technical description

3.3 Technical data You will find the technical data and setting values for your machine in
the test reading supplied. You will find the most important data in
3.3.1 Electromagnetic brief on the rating plates attached to the machine and to the boom.
compatibility (EMC)
The certificate of compliance with EMC protection requirements
has been issued in accordance with Article 6 paragraph 2 of
Council Directive 2004/108/EC on the approximation of the laws
of the member states relating to electromagnetic compatibility,
implemented in Germany by the law concerning the electromagnetic
compatibility of devices, dated 26th February 2008 (EMVG,
section 4).

Customer: Putzmeister Concrete Pumps GmbH
MaxĆEythĆStrasse 10
To be inspected: 72631 Aichtal, Germany
Inspection location:
TruckĆmounted concrete pump
Test report no.:
Date of inspection: MBtech EMC GmbH, Waiblingen,
Germany
Absorberhalle H

P130577

2nd May 2013

3ĂĊĂ6 BP23_217_1305EN

General technical description

Inspection type Individual tests Basic standard Range Requirement Result

Inspection of radiated Radio interference EN 13309:2010 30 Ć 1000 MHz Broadband and
broadband/narrowĆ field intensity narrowband,
band electromagnetic horizontal and
interference vertical, leftĆ and passed
rightĆhand side of
the truck

RF interfering field EN 13309:2010 20 Ć 1000 MHz 30 V/m + AM
1 kHz/80%
Inspection of interĆ ISO 11452 passed
ference resistance 30 V/m + PM,
217 Hz/577 µs ED
800 Ć 2000 MHz

Measurement of interĆ Interference EN 13309:2010 External: Air discharge/ passed
ference resistance resistance against ISO 10605 150 pF/330 Ohm contact: +/− 8 kV,
discharge of static 10 discharges,
electricity Internal: 5 sec. rest
330 pF/2 KOhm

Compliance with the fundamental requirements of the EMC directive
was confirmed on the basis of the documents described in test
report no. P130577. The inspections carried out with regard to
radiated interference and interference resistance were passed.

BP23_217_1305EN 3ĂĊĂ7

General technical description

3.3.2 Machine rating plate The following rating plate is attached to the machine:

5

1 Betonpumpe

2 BSF 42–5.16 H

3 210109187

46
78

BP22_830_1005EN 1

No. 0 Designation
1 Designation of the machine
2 Machine model
3 Machine number
4 Maximum fluid pressure in the hydraulic system [bar]
5 Year of manufacture
6 Maximum delivery pressure [bar]

The following data depend on the machine model
7 Total weight [kg]
8 Delivery line diameter [mm]

Note
If specific details do not apply to a machine, the relevant fields are
blank. With truckĆmounted concrete pumps, the weight specified
by the vehicle manufacture applies as per 76/114/EEC:
"Official permitted total weight specified by manufacturer".

3ĂĊĂ8 BP22_830_1005EN

General technical description

3.3.3 Boom rating plate The following plate is attached to the boom:

10 15
11 16
1
12
2 13
14
3 17

18
4 19

20
5

6

7

8

9

BP22_598_1004EN 1

BP22_598_1004EN 3ĂĊĂ9

General technical description

No. 0 Placing boom data
1 Model
2 Placing boom no.
3 Material no. (MN)
4 Year of manufacture
5 Horizontal reach max.
6 Vertical reach max.
7 Length of end hose max.
8 Hydraulic pressure max.
9 Delivery pressure max.
Placing boom delivery line data

10 MN (material number)
11 DN (nominal diameter)
12 Model (maximum permitted outside diameter

and wall thickness of the delivery line)
13 Coupling type (AL = aluminium, ST = steel)
14 L1 − L6: Arm assembly adapter pipe lengths

End hose data
15 MN (material number)
16 DN (nominal diameter)

Pump delivery line data
17 MN (material number)
18 DN (nominal diameter)
19 Model (maximum permitted outside diameter

and wall thickness of the delivery line)
20 V1 − V10: Pump − riser pipe adapter pipe lengths

3ĂĊĂ10 BP22_598_1004EN

General technical description

3.3.4 Sound pressure level The sound pressure level produced by the machine is given below in
accordance with Directive 2006/42/EU.

3.3.5 Sound power level The place of work is from the remote control. The machine has a
sound pressure level of 85 dB(A) within a radius of 16Ăm. Ear deĆ
fenders must be worn in the vicinity of the machine since the sound
pressure level can be higher. The sound pressure was determined
on the basis of Directive 2000/14/EU.

The sound power level produced by the machine is given below in
accordance with Directive 2000/14/EU.

The plate illustrated below, which shows the measured sound power
level of the machine, is located near the machine’s rating plate.

BP21_359_1001EN 1

No. 0 Designation

LWA Sound power level
dB Value in decibels

BP21_359_1001EN 3ĂĊĂ11

General technical description

What does this mean? A uniform method of measuring the noise generated by a machine
(Directive 2000/14/EU) has been applicable throughout Europe since
1ĂJanuary 2002.

Sound pressure level In the past, the sound pressure level of the machine was stated. To
measure this level, the sound produced by the machine was
measured at several measuring points and at a fixed distance and
height. The average value was determined from these measureĆ
ments and converted to a theoretical distance. The sound pressure
level stated for the machine therefore always referred to a theoretical
distance and was given in dB(A).

Disadvantage: the actual sound pressure level is higher if you stand
closer to the machine.

Sound power level Nowadays, the sound power level of the machine is stated. To calcuĆ
late this, an imaginary sphere of defined diameter is centered on the
machine. The sound pressure level is measured again at several
measuring points on this sphere. To obtain the value for the sound
power level, the calculated sound pressure level is now multiplied by
the surface area of the imaginary sphere. The sound power level is
given in dB.

Advantage: as you approach the machine, although the sound presĆ
sure level increases, the surface area of the imaginary sphere deĆ
creases. This means that multiplying the two figures gives the same
sound power level as before.

3ĂĊĂ12 BP21_359_1001EN

3.3.6 Reaches General technical description

The MĂ42 RZ has the reaches listed below.

180_ 3

246_ 180_

5.5_ 90_

2 4
1
365_

5

235_

BP22_925_1102EN 1

1 Horizontal reach from middle of slewing unit 37.3Ăm
2 Horizontal reach from front edge of truck 34.5Ăm
3 Vertical reach 41.6Ăm
4 Unfolding height
5 Depth of reach with 4Ăm end hose 8.6Ăm
31.0Ăm

BP22_925_1102EN 3ĂĊĂ13

General technical description

3.4 Description of This section is intended to help you understand the functions of the
the functions machine so that you can restrict the field of the machine’s applicaĆ
tions to suitable areas and avoid errors in operation.
3.4.1 Boom
The boom arms are of box construction. They are actuated hydrauliĆ
3.4.2 Delivery line cally.
Arm hinges with excellent angular range, in combination with the
3.4.3 Support legs powerful slewing gear with its wide slewing range, provide very flexĆ
3.4.4 Hydraulic control ible movement.

The delivery and riser lines comprise standard straight pipe sections
and elbows. These are thus easily replaced.
Standard Putzmeister clamp couplings serve as both pivot joints and
pipe connectors.
The elbow pivot at the end of the boom acts as a brake on the falling
concrete and reduces the wear on the end hose. Thanks to its steel
corded fabric, this hose is suitable for an operating pressure of up to
85 bar.

The telescopic support legs swing out and are fitted with fully hyĆ
draulic support cylinders thus giving the stability required.

All boom movements are effected hydraulically. All boom cylinders
have two integral safety valves to provide protection against overĆ
loading or rupture of the hydraulic lines.
The hydraulic fluid supply is sufficient to operate a number of cylinĆ
ders simultaneously. The hydraulic control can be operated from the
concrete pump or by using a portable remote control unit.

The control valves are actuated:
− electrically; or
− electro−pneumatically; or
− electro−hydraulically.

The hydraulic fluid tank is integrated in the boom pedestal.
Compressed air and control current are taken from the truck.

3ĂĊĂ14 BP02_074_9605EN

General technical description

3.4.5 Pump PM pumps are driven hydraulically through diesel engine powered
3.4.6 S transfer tube fluid pumps. The delivery pistons (4) are hydraulically linked together
through the driving cylinders (5). They operate in a push−pull mode.
The returning delivery piston sucks the concrete in. At the same
time, the advancing delivery piston forces the concrete sucked in
previously into the delivery line through the pressure pipe or the
pressure elbow (1).
The pump switches over at the end of the stroke. The transfer tube
(2) swings over the full delivery cylinder (3) and the delivery pistons
(4) reverse their direction of movement.

Reverse stroke
Reversal of the delivery pistons’ (4) movement in the middle of the
stroke movement. The transfer tube (2) does not switch. The conĆ
crete is sucked back from the delivery line into the hopper.

Switchover
Reversal of the delivery pistons’ (4) direction in the middle of the
stroke movement. The transfer tube (2) switches over. The concrete
is still pumped without interruption. Switching over helps prevent the
formation of blockages.

5 21

4 12501502
3
3ĂĊĂ15
1 Pressure elbow
2 Transfer tube
3 Delivery cylinder
4 Delivery piston
5 Drive cylinder

BP02_030_9605EN

General technical description

3.5 General conditions General conditions are control values, which are partly given as
for using a concrete physical conditions and which set limits for using a concrete pump.
pump The following general conditions must be observed when using a
concrete pump.
3.5.1 Service life
If operated, maintained and inspected correctly, and if original or
equivalent spare parts and accessory components are used, the
service life is 15 years.

Truck-mounted concrete pump standard
Output [m3]/year 30000
Operating hours [h]/year 400
Uses per day 3
Uses per year 750

Truck mixer concrete pump standard
Output [m3]/year 15000
Operating hours [h]/year 200
Uses per day 1
Uses per year 250

stationary concrete pump standard
Stationary boom
Delivery line valve 20000
400
Output [m3]/year 1
250
Operating hours [h]/year

Uses per day

Uses per year

3ĂĊĂ16 BP22_827_1212EN

General technical description

3.5.2 Site of use A concrete pump is designed for industrial use on outdoor construcĆ
3.5.3 Height of job tion sites, or indoors with adequate ventilation. It must not be used in
areas where there is a potentially explosive atmosphere.

Putzmeister must be contacted if the concrete pump is to be used at
a height greater than that given here. The standard reference level is
the European standard elevation zero (NHN).

Pump type maximum height
of job

Piston pump with internal combustion 2500 m
engine,
Delivery line valve 1000 m (v 40 °C)
2000 m (v 30 °C)
Piston pump with electric motor,
Stationary boom

Rotor pump 2000 m

BP22_827_1212EN 3ĂĊĂ17

General technical description

3.5.4 Operating Putzmeister must be contacted if the concrete pump is to be used
temperature outside the given temperature ranges.

Machine model min [° C] max
[° C]

Truck−mounted concrete pump, − 15 + 50
Delivery line valve
− 8 + 45
Truck mixer concrete pump − 8 + 40
(with piston pump) + 3 + 40

Stationary concrete pump with diesel
engine *

Stationary concrete pump with electric
motor **
Stationary boom **

General rotor pump ***

* Limited due to the diesel engine without preĆheating device. When
using below −8 °C, a preĆheating device must be installed.
** Limited due to supply cable during overload. Temperature ranges
can be extended if special measures are applied.
*** Limited due to the vacuum pump and rotor hose.

3ĂĊĂ18 BP22_827_1212EN

General technical description

3.6 Electrical control The electrical control devices and operating elements on this
devices machine are described on the following pages. The summary at the
start of this chapter will show you where the various control devices
are located on the machine. The symbols used on the electrical
control devices are described in one of the preceding sections.

The electrical control devices may include the following components,
depending on the equipment on your machine.
− Control cabinet
− OSS equipment
− Control panel
− Centralized lubrication system
− Cable remote control
− Radio remote control system
− Distributor casing for inductive/magnetic switches

Note
Further control devices and components are described in the
Hydraulic control devices" (from page 3ĂĊĂ125) and OtherĂcompoĆ
nents" (from page 3ĂĊĂ133) sections.

BP02_388_9704EN 3ĂĊĂ19

General technical description

3.6.1 Central modular The central modular control cabinet is illustrated below. You will find
control cabinet the description of any additional door modules and their control and
operating elements fitted in place of the blanking plates on the folĆ
lowing pages.

1 1 5
1 1
2
3 4

No. 0 Operating/ Meaning/Function BP22_929_1110EN 1
control element
1 Blanking plate Options for door modules Belongs
Locally latched toggle with no.:
2 switch Local control − 0 − Remote control
Female connector
3 Ergonic Graphic Display Diagnosis
4 Female connector Displaying and setting operating states
5 Connection for remote control

3ĂĊĂ20 BP22_929_1110EN

General technical description

Special features of the control cabinet

Closing and locking the The control cabinet is located in a stowage compartment. You must
control cabinet always lock this stowage compartment to prevent any unauthorised
person switching the control system over.

Caution
Depending on the design, the stowage compartment cannot be
closed on some machines when the cable remote control is used. In
such cases, the machine operator must take suitable measures to
ensure that no unauthorized persons gain access to the control cabiĆ
net.

Diagnostics socket To capture data from the machine, a diagnostics unit can be conĆ
nected to the diagnostics socket by authorized and qualified personĆ
nel.

Locally latched toggle To use a locally latched toggle switch, you must first pull it out and
switches then push it towards the symbol.

Switchover from local to The EMERGENCY STOP circuit is activated automatically when you

remote control switch over from local to remote control. You must operate the horn

to deactivate the EMERGENCY STOP circuit.

BP22_929_1110EN 3ĂĊĂ21

General technical description

3.6.2 OSS equipment The door module for the OSS equipment (OSS = One−Side−Support)
is illustrated below. This equipment allows the machine to be set up
in a narrow space. The flashing beacons for the working range are
attached to the boom pedestal at the front.

13

No. Operating/ 2 4
0 control element
1 Green indicator lamp Meaning/Function BP21_203_0703EN 1
2 Keyswitch Left OSS working range selected
3 Green indicator lamp Select OSS working range Belongs
4 Toggle switch Right OSS working range selected with no.:
Cancel OSS working range
Switch off OSS flashing beacon

3ĂĊĂ22 BP21_203_0703EN

General technical description

3.6.3 Ergonic Graphic The Ergonic Graphic Display (EGD) is a graphic display and
Display control unit on the control cabinet. The EGD allows you to determine
the operating state of the machine. You can use the EGD operating
Appearance of the elements to navigate in the menu structure and to make settings.
symbols
The symbols used in the display appear differently depending on the
meaning.

Colour / Appearance Meaning

white background Standard appearance
green background Function is active
yellow background Limit reached, warning
red background Fault
The fault must be remedied before
black frame the operation can be restarted on
redĆblack frame the machine.
(thin line) Standard appearance
The symbol can be selected, the
red frame sensor can be deactivated due to
(thick line) fault and emergency operation can
struck through be activated
flashing The symbol is selected

The sensor is deactivated
Fault
The fault can be overridden by
deactivating the sensor; the machine
with then go into a defined emergĆ
ency operation.

BP22_949_1104EN 3ĂĊĂ23

General technical description

EGD and operating
elements

2

3
1

4

55 5

BP22_949_1104EN 1

No. 0 Operating/ Function / meaning
control element
1 Ergonic Graphic Display MenuĆdriven displays and adjustable functions are
2 (EGD) shown in the EGD.
3 PushĆbutton HOME" function key
Help" function key
PushĆbutton Function button F4 for selecting or setting symbols and
numerical values.
4 Rotary/pushĆbutton Function buttons F1, F2, F3 for navigating between
menus
5 PushĆbutton

3ĂĊĂ24 BP22_949_1104EN