Manual safety regulation_EN

Maintenance card
04−014

Page 4 of 4

5ĂĊĂ68 WK04_014_1109EN

Maintenance card
04−018

Page 1 of 10

04–018 Hydraulic fluid filter change This maintenance card describes how to change the elements for
the vacuum filter and the vacuum return flow filter. You will find the
maintenance intervals in the maintenance summary at the start of
this chapter.

Note
There are specific risks of accident associated with maintenance,
inspection and repair work. For this reason, read the chapter
Safety regulations" and the description of the Residual risks during
maintenance, inspection and repair work" at the start of the chapter
entitled Maintenance" (i.e. this chapter).

No further maintenance cards required.

No special tools required.

Note
Cleanliness is of the utmost importance in the maintenance of
hydraulic systems. Prevent any type of dirt or contamination from
entering the system. Even small particles may cause valves to be
scored, pumps to seize and throttle, and control bores to become
blocked.

Hydraulic fluid barrels must stand for some time before the fluid
is removed from them. Do not roll the hydraulic fluid barrels to the
tapping point. Clean bungs, filler lids and the area around them
before opening.

If possible, you should use a charging set to fill up the hydraulic
system. Never leave the tank lid open longer than necessary.

WK04_018_1404EN 5ĂĊĂ69

Maintenance card
04−018

Page 2 of 10

Caution
Filter elements freely available on the market have too low a flow
rate. You must, therefore, only ever use original Putzmeister filter
elements in order to prevent damage to the machine.

You must never attempt to clean filter elements. These must always
be replaced.

Environmental protection
All operating equipment and functional fluids, e.g. oils (including
biologically degradable oils), filters and auxiliary materials must be
carefully collected and disposed of separately, both from each other
and from other waste. Different categories of oil must also be kept
separately from each other. Nationally and regionally applicable
disposal regulations must be observed for these materials.

Preparation The following tasks must be carried out before changing the filter:

" Switch off the hydraulic pumps.ā
" Switch the motor off.
" Dump the fluid pressure completely.
" Switch off the remote control.

Danger
Escaping pressurized hydraulic fluid can cause serious or fatal
injuries. Relieve the pressure in the hydraulic system and the accuĆ
mulator.

" Secure the machine against being started by unauthorized
persons − if you have any keyĆoperated switches, remove the
key and disconnect the supply voltage.

" Secure your working area and fix information plates to the
locked controls and setting devices.

5ĂĊĂ70 WK04_018_1404EN

Removing the Maintenance card
vacuum filter 04−018

Page 3 of 10

Caution
The vacuum filter and vacuum return flow filter are interconnected
by a lead with a check valve. Hydraulic fluid from the vacuum filter
can escape via the vacuum return flow filter. When changing the
filter element, proceed in the specified sequence:
ć Remove the vacuum filter element.
ć Replace the vacuum return flow filter element.
ć Change the vacuum filter element.
ć Bleed the vacuum return flow filter.

3

1 4

2 WK04_018_1404EN 1

5

Pos.0 Designation
1 Cover
2 Hexagon nut
3 Plug
4 Filter element
5 Magnetic rod

WK04_018_1404EN 5ĂĊĂ71

Maintenance card
04−018

Page 4 of 10

" Place a container under the filter casing to allow you to catch
the escaping hydraulic fluid.

" Unscrew the hexagon nuts as far as the stop and remove the
filter element without turning it to the stop.
å A shutĆoff valve automatically interrupts the hydraulic fluid
supply.

" Open the upper stopper to provide an air supply.

" Turn the cover antiĆclockwise and remove it.

" Leave the hydraulic fluid to run out of the filter casing.

" Pull out the filter element.

Note
Observe the sequence and proceed to change the vacuum return
flow filter.

5ĂĊĂ72 WK04_018_1404EN

Maintenance card
04−018

Page 5 of 10

Changing the vacuum
return flow filter

1
2

3

WK04_018_1404EN 2

Pos.0 Designation

1 Air supply plug
2 Cover
3 Drain plug

" Place a container with a minimum capacity of 10 l under the
drain plug on the cover to allow you to catch the escaping
hydraulic fluid.

" Open the upper stopper to provide an air supply.

" Open the drain plug and allow the hydraulic fluid to run out of
the filter casing.

WK04_018_1404EN 5ĂĊĂ73

Maintenance card
04−018

Page 6 of 10

3

2
1

WK04_018_1404EN 3

Pos.0 Designation

1 Cover
2 Separation plate
3 Filter element

" Unscrew the cover.

" Pull the separation plate out, by turning it slightly antiĆclockĆ
wise.
å More hydraulic fluid will escape.

" Pull the filter element out, by turning it slightly antiĆclockwise.

5ĂĊĂ74 WK04_018_1404EN

Maintenance card
04−018

Page 7 of 10

" Examine all components for mechanical damage, paying
particular attention to the sealing surfaces, thread and OĆrings.

" Replace any damaged components, if necessary.
" Lubricate the sealing surfaces, thread and OĆrings with clean

hydraulic fluid.

Caution
The filtering process causes contamination particles to accumulate
in the filter casing. You must therefore clean the filter casing
thoroughly before refitting the new filter element, as otherwise
the new filter element will rapidly become clogged again.

" Clean the filter casing thoroughly with a clean cloth.
" Fit a new filter element, by turning it slightly clockwise.
" Fit the separation plate on the filter element, by turning it

slightly clockwise.

WK04_018_1404EN 4

" Screw in the cover.
" Screw in the drain plug.

WK04_018_1404EN 5ĂĊĂ75

Maintenance card
04−018

Page 8 of 10

Fitting the
vacuum filter

" Wipe the magnetic rod lengthways with a clean cloth.

" Examine all components for mechanical damage, paying
particular attention to the sealing surfaces, thread and OĆrings.

" Replace any damaged components, if necessary.

" Lubricate the sealing surfaces, thread and OĆrings with clean
hydraulic fluid.

Caution
The filtering process causes contamination particles to accumulate
in the filter casing. You must therefore clean the filter casing
thoroughly before refitting the new filter element, as otherwise
the new filter element will rapidly become clogged again.

" Clean the filter casing thoroughly with a clean cloth.
" Fit a new filter element on the magnetic rod.
" Place the cover on the casing, turn it clockwise and refit it fully.
" Securely screw in the cover.

5ĂĊĂ76 WK04_018_1404EN

Maintenance card
04−018

Page 9 of 10

Bleeding the vacuum
return flow filter

WK04_018_1404EN 5

" Open a plug on both the suction side and the return side of the
filter casing.

" Fill up with new hydraulic fluid via the openings, until the filter
casing is full.

" Screw the plugs back in.

" Start the machine up briefly (approx. 5 minutes)

" Open a plug on both the suction side and the return side of the
filter casing.

" Check the fluid level in the filter casing again.
å Fill up with hydraulic fluid as required, until the filter casing
is full.

WK04_018_1404EN 5ĂĊĂ77

Maintenance card
04−018

Page 10 of 10

5ĂĊĂ78 WK04_018_1404EN

Maintenance card
06−047

Page 1 of 10

06–047 Delivery piston replacement This maintenance card describes how to replace the delivery pistons
on the dual piston end–of– on a 2−KEP system. In the 2−KEP (piston end−of−travel positioning)
travel positioning system system, there is a ball valve fitted in the stroke correction line of each
drive cylinder. You will find the maintenance intervals in the maintenĆ
ance summary at the start of this chapter.

Note
There are specific risks of an accident associated with maintenance,
inspection and repair work. For this reason, read the chapter "Safety
regulations" and the description of the "Residual risks during mainĆ
tenance, inspection and repair work" at the start of the chapter enĆ
titled "Maintenance" (i.e. this chapter).

No further maintenance cards required.

No special tools required.

Note
Damage to the delivery pistons must be rectified without delay.
Putzmeister accepts no warranty claims for damage to the machine
resulting from failure to properly observe the maintenance regulaĆ
tions.

Danger
Secure the working area. Place warning notices on blocked control
and setting devices.

WK06_047_1109EN 5ĂĊĂ79

Maintenance card
06−047

Page 2 of 10

Shutting down the You will have to start up and shut down the machine a number of
machine times when replacing the delivery pistons. The operations necessary
for this task are described below and must be carried out conscienĆ
tiously. Execute all machine functions from the cable remote control.

Proceed as follows to shut down the machine:

" Switch off the engine.
" Press the EMERGENCY STOP button.
" Dump the pressures completely.

Danger
Dump the accumulator pressure completely in systems with pressure
accumulators.

Starting up the Proceed as follows to start up the machine:
machine
" Unlock the EMERGENCY STOP button and sound the horn.
" Switch the engine on.

Caution
Do not switch the pump on until you are called upon to do so.

5ĂĊĂ80 WK06_047_1109EN

Maintenance card
06−047

Page 3 of 10

Blocking the drive cyl- You must block each associated drive cylinder in the end position
inders in the end posi- before you are able to remove the delivery pistons.
tion
Note
To lock the drive cylinders in the end position with minimum wear",
set the pumping rate below 50% and the engine speed to approxiĆ
mately half the maximum value.

Closing the stroke Each drive cylinder stroke correction line has a ball valve (KEP) that
correction lines is fitted open (markings parallel to the line) ex works and is locked
against turning. It is necessary to close the stroke correction line to
the drive cylinder from which you are removing the delivery piston
using the ball valve.

20202301

The works fits the ball valve (KEP) in the open state

WK06_047_1109EN 5ĂĊĂ81

Maintenance card
06−047

Page 4 of 10

1

2

20202302

1 As−fitted position secured against rotation
2 Rotate position

" Undo the bolt on the handle and remove the handle.
" Lift up the guide washer and refit it rotated through 90_ā.

5ĂĊĂ82 WK06_047_1109EN

Maintenance card
06−047

Page 5 of 10

WK06_047_1109EN 1

Ball valve (KEP) when closed

" Replace the handle.

" Press the Change−over" switch when the concrete pump is
running and hold it down until the concrete pump switches off.

" Close the ball valve once the two drive cylinders have stopped
moving.

Note
Just after you have closed the ball valve, there is a possibility that
one of the drive cylinders may move again briefly until both drive cylĆ
inders are finally in mechanical end position.

" Now switch the concrete pump off.
" Then you can release the Change−over" switch.

WK06_047_1109EN 5ĂĊĂ83

Maintenance card
06−047

Page 6 of 10

Piston replacement When replacing pistons you may work with the remote control on the
platform.

1 232 4

5 10600301

1 Piston rod flange
2 Fastening bolts
3 Securing wire
4 Delivery piston
5 Spacer flange

" Shut the machine down.

" Drain the water from the water box and remove the cover.

" Start the machine up.

" Move the drive piston of the delivery piston to be removed to
its end position. The spacer flange must be fully visible in the
water box.

" Shut the machine down.

" Remove the securing wire from the fastening bolts.

5ĂĊĂ84 WK06_047_1109EN

Maintenance card
06−047

Page 7 of 10

1

10600701

1 Fastening bolts

" Unscrew the fastening bolts for the spacer flange from the
drive piston rod and from the delivery piston and remove the
spacer flange.

" Start the machine up.

" Slowly bring the drive piston rod up to the delivery piston.

" Shut the machine down.

WK06_047_1109EN 5ĂĊĂ85

Maintenance card
06−047

Page 8 of 10

1 10600800
1 Pulling bolts

" Remove the protective caps from the two pulling bolts and bolt
the delivery piston to the drive piston using the two pulling
bolts.

" Start the machine up.

" Pull the delivery piston completely out of the delivery cylinder.

" Shut the machine down.

" Undo the threaded joint and remove the old delivery piston.

" Thoroughly clean the delivery piston edge at the end of the
water box.

Caution
Do not use any hard objects or caustic cleaning agents to clean the
delivery cylinder. These might damage the chrome coating.

5ĂĊĂ86 WK06_047_1109EN

Maintenance card
06−047

Page 9 of 10

" Grease a new delivery piston heavily with acid−free grease
(e.g. Vaseline).

" Bolt the new delivery piston to the drive cylinder using the two
pulling bolts.

" Start the machine up.
" Slowly advance the drive piston rod and push the new delivery

piston carefully into the delivery cylinder. The pulling bolts must
remain freely accessible.

" Shut the machine down.
" Unscrew the pulling bolts and replace the protective caps.
" Start the machine up.
" Retract the drive piston rod sufficiently for the spacer flange to

fit between the delivery piston and the drive piston.

" Shut the machine down.
" Insert the spacer flange and fasten all the bolts.
" Tighten the bolts to the specified tightening torques and seĆ

cure them with a stainless steel wire.

WK06_047_1109EN 5ĂĊĂ87

Maintenance card
06−047

Page 10 of 10

Opening the stroke
correction lines

20202301

Open the ball valve (KEP) and secure it against rotation

" Open the ball valve (KEP) when delivery piston replacement is
completed.

" Replace the guide washer so that it is blocked in position, fit
the handle and bolt it down.

Caution
The ball valves must be opened and secured by the guide washers
when the machine is being operated.

The pump may not be able to change the stroke over any longer if
the ball valve is closed.

" Then carry out a test run.

Note
Replace the second delivery piston in the same way.

5ĂĊĂ88 WK06_047_1109EN

07–001 Lubricating the Maintenance card
S transfer tube 07−001

Page 1 of 2

This maintenance card describes the lubrication of all lubrication
points on the transfer tube if you do not have a centralized lubricaĆ
tion system. You will find the maintenance intervals in the maintenĆ
ance summary at the start of this chapter.
Note
There are specific risks of an accident associated with maintenance,
inspection and repair work. For this reason, read the chapter "Safety
regulations" and the description of the "Residual risks during mainĆ
tenance, inspection and repair work" at the start of the chapter enĆ
titled "Maintenance" (i.e. this chapter).

No further maintenance cards required.

The following special tools are required:
Grease gun

Note
Use a grease with the marking K2K in accordance with DIN 51 502,
NLGI Class 2.

WK07_001_1109EN 5ĂĊĂ89

Maintenance card
07−001

Page 2 of 2

Lubrication intervals You should grease the lubrication points one to three times daily, unĆ
less a different interval is specified. You should apply the grease until
you can see it emerging.

30300103

Transfer tube and plunger cylinder lubrication diagram

5ĂĊĂ90 WK07_001_1109EN

Maintenance card
07−068

Page 1 of 8

07–068 Replacing the transfer tube This maintenance card describes how to replace the transfer tube
bearing bearing. You will find the maintenance intervals in the maintenance
summary at the start of this chapter.

Note
There are specific risks of an accident associated with maintenance,
inspection and repair work. For this reason, read the chapter "Safety
regulations" and the description of the "Residual risks during mainĆ
tenance, inspection and repair work" at the start of the chapter enĆ
titled "Maintenance" (i.e. this chapter).

No further maintenance cards required.

No special tools required.

MA The tightening torques can be found in the corresponding
Spare parts list.

Danger of crushing
A pressurized hydraulic system may cause the machine to move
suddenly, which may result in you being seriously injured if you are
working on the machine. To avoid risk, shut the machine down and
secure it against unauthorized or accidental starting.

Caution
Use only suitable lifting equipment for lifting components.

WK07_068_1109EN 5ĂĊĂ91

Maintenance card
07−068

Page 2 of 8

Note
Wear parts must be replaced in the event of one of the following:
ć Severe wear is visible
ć Concrete is seeping out

Shutting down the When maintenance work is carried out, the machine must have been
machine shut down. The operations necessary for this task are described
below and must be carried out conscientiously. Use the remote conĆ
trol here.

Shut down the machine as follows:

" Switch off the engine.
" Dump the pressures completely.

Danger
Dump the accumulator pressure completely in systems with pressure
accumulators.

Starting up the The machine may be started up differently depending on the maĆ
machine chine model. When you are starting up a truck−mounted concrete
pump, proceed as follows:

" Unlock the EMERGENCY STOP button and sound the horn.
" Switch the engine on.

Caution
Do not switch the pump on until you are called upon to do so.

5ĂĊĂ92 WK07_068_1109EN

Maintenance card
07−068

Page 3 of 8

Removing the transfer The S transfer tube is mounted in the transfer tube bearing in the

tube bearing rear wall of the hopper.

" Shut the machine down.
" Open the grille on the hopper and secure the grille.
" Attach suitable lifting gear to the S transfer tube.
" Remove the lubrication lines from the transfer tube bearing.

12

3 45 617

WK07_068_1109EN 1

No. 0 Designation

1 Fastening bolts
2 Transfer tube bearing
3 Wedge
4 Spring pin
5 Retaining bolt for hinged elbow
6 Pulling bores with jacking thread
7 Hinged elbow

Danger
The hinged elbow (7) folds open immediately when the wedge (3) is
removed from the retaining bolt (5). This presents a risk of injury.
Hold the hinged elbow (7) securely in position when removing the
wedge (3).

WK07_068_1109EN 5ĂĊĂ93

Maintenance card
07−068

Page 4 of 8

" Release the wedge (3) by removing the spring pins (4).
" Remove the wedge (3) from the retaning bolt (5).
" Open the hinged elbow (7).
" Unscrew the two fastening bolts (1) on the transfer tube bearĆ

ing (2).
" Insert the two supplied pulling bolts into the pulling bores (6).

å The transfer tube bearing (2) is forced out.
" Inspect the gasket set on the transfer tube bearing (2) for wear

and replace the gasket set if necessary.

5ĂĊĂ94 WK07_068_1109EN

Maintenance card
07−068

Page 5 of 8

Replacing the transfer
tube bearing gasket
set

WK07_068_1109EN 2

Bending the grooved ring to make installation easier

Caution
The mounting position for the gasket set in the transfer tube bearing
can be found in the corresponding spare parts sheet.

" Grease the new gasket set.
" Bend the grooved ring to make installation easier.
" Insert the gasket set as shown on the spare parts sheet.

Note
Clean the transfer tube bearing before refitting and grease the seals.
Check the lubricant bores, in particular, for proper functioning. This
is done by connecting the lubrication lines and forcing grease
through the openings.

WK07_068_1109EN 5ĂĊĂ95

Maintenance card 12
07−068

Page 6 of 8

Fitting the transfer
tube bearing

34 516

WK07_068_1109EN 3

No. 0 Designation

1 Fastening bolts
2 Transfer tube bearing
3 Wedge
4 Retaining bolt for hinged elbow
5 Pulling bores with jacking thread
6 Hinged elbow

Note
Note the position of the lubrication openings when installing the
transfer tube bearing (2).

" Place the transfer tube bearing (2) onto the S transfer tube
outlet and screw securely in position.

5ĂĊĂ96 WK07_068_1109EN

Maintenance card
07−068

Page 7 of 8

Close hinged elbow The hinged elbow must be closed as follows:

1

2 23

54

6 WK07_068_1109EN 4

No. 0 Designation
1 Inscription "0" or recess
2 Retaining bolt for hinged elbow
3 Hinged elbow
4 Wedge
5 Tie bolt for retaining bolt (2)
6 Spring pin

WK07_068_1109EN 5ĂĊĂ97

Maintenance card
07−068

Page 8 of 8

Note
The retaining bolt (2) must be screwed to the tie bolt (5) as shown in
the above illustration (inscription "0" or recess (1) facing upwards).
Only then can the wedge (4) for closing the hinged elbow be fitted.

" Check that the retaining bolt (2) is seated securely.
" Check the mounting position of the retaining bolt (2).
" Close the hinged elbow (3) with the wedge (4).
" Secure the wedge (4) using the spring pin (6).

5ĂĊĂ98 WK07_068_1109EN

07–070 Replacing the switching Maintenance card
shaft bearing (flanged 07−070
bearing)
Page 1 of 16

This maintenance card describes how to replace the switching shaft
bearing (flanged bearing). You will find the maintenance intervals in
the maintenance summary at the start of this chapter.

Note
There are specific risks of an accident associated with maintenance,
inspection and repair work. For this reason, read the chapter "Safety
regulations" and the description of the "Residual risks during mainĆ
tenance, inspection and repair work" at the start of the chapter enĆ
titled "Maintenance" (i.e. this chapter).

See also the maintenance cards:
Adjusting the S transfer tube

No special tools required.

MA The tightening torques can be found in the corresponding
Spare parts list.

Danger of crushing
A pressurized hydraulic system may cause the machine to move
suddenly, which may result in you being seriously injured if you are
working on the machine. To avoid risk, shut the machine down and
secure it against unauthorized or accidental starting.

Caution
Use only suitable lifting equipment for lifting components.

WK07_070_1109EN 5ĂĊĂ99

Maintenance card
07−070

Page 2 of 16

Note
Wear parts must be replaced in the event of one of the following:
ć Severe wear is visible
ć Concrete is seeping out

Shutting down the When maintenance work is carried out, the machine must have been
machine shut down. The operations necessary for this task are described
below and must be carried out conscientiously. Perform all machine
functions using the remote control.

Proceed as follows to shut down the machine:

" Switch off the engine.
" Dump the pressures completely.

Danger
Dump the accumulator pressure completely in systems with pressure
accumulators.

5ĂĊĂ100 WK07_070_1109EN

Starting up the Maintenance card
machine 07−070

Page 3 of 16

The machine may be started up differently depending on the maĆ
chine model. When you are starting up a truck−mounted concrete
pump, proceed as follows:

" Unlock the EMERGENCY STOP button and sound the horn.
" Switch the engine on.

Caution
Do not switch the pump on until you are called upon to do so.

When you are starting up a stationary concrete pump, proceed as
follows:

" If there is a throttle, set it to one third.
" Start up the engine.
" Select a low output.
" Switch the pump on.

WK07_070_1109EN 5ĂĊĂ101

Maintenance card
07−070

Page 4 of 16

Overview

1 23 45 6 7 8 9 10 11

14 13 12

WK07_070_1109EN 1

No. 0 Designation

1 Pulling bore for ball cup
2 Ball cup
3 Hydraulic port
4 Plunger cylinder
5 Retaining plate
6 Retaining plate fastening bolts
7 Switch lever
8 Clamping bolts with nuts
9 Disc
10 Switching shaft
11 Hexagon nut
12 Flanged bearing
13 Pulling bore for flanged bearing (two diagonally opposite

each other)
14 Fastening bolt for flanged bearing (covered)

5ĂĊĂ102 WK07_070_1109EN

Maintenance card
07−070

Page 5 of 16

Removing the switch- The switching shaft (10) of the S transfer tube is supported in the
ing shaft bearing flanged bearing (12) in the front wall of the hopper.
(flanged bearing)

" Shut the machine down.

" Remove any lubrication lines from the retaining plate (5) and
flanged bearing (12).

WK07_070_1109EN 2

Unbolting the retaining plate

" Screw the fastening bolts (6) out of the retaining plate (5) and
remove the retaining plate (5). (You will have to replace the
lock washers on the fastening bolts (6) with new ones on reasĆ
sembly.)

WK07_070_1109EN 5ĂĊĂ103

Maintenance card
07−070

Page 6 of 16

Environmental protection
All functional fluids and operating materials, e.g. oils (including bioĆ
logically degradable oils), filters and auxiliary materials must be
carefully collected and disposed of separately, both from each other
and from other waste. Different categories of oil must also be kept
separately from each other. Nationally and regionally applicable disĆ
posal regulations must be observed for these materials.

" Place an oil sump pan under the working area.
" Place a container under the bulkhead union as well.
" Unscrew the hydraulic hose that leads to the plunger cylinder

from the bulkhead union.

" Catch the hydraulic fluid flowing out of the hydraulic line and
hydraulic hose.

" Seal the hydraulic line with a plug.

5ĂĊĂ104 WK07_070_1109EN

Maintenance card
07−070

Page 7 of 16

1 2 34

WK07_070_1109EN 3

No. 0 Designation
1 Plunger cylinder
2 Locking plate
3 Ball cup
4 Pulling bore

Note
You can press a plunger cylinder (1) out of the ball cup (3) from the
piston side as shown. If the ball cup is worn, you can screw a bolt
into the pulling bore (4) for the ball cup and press out the plunger
cylinder with the ball cup.

" Remove the locking plate (2).
" Press the piston rod on the plunger cylinder (1) back.
" Catch the hydraulic fluid flowing out of the hydraulic hose.
" Remove the plunger cylinder (1) and hydraulic hose.

WK07_070_1109EN 5ĂĊĂ105

Maintenance card
07−070

Page 8 of 16

" If required, remove the hydraulic hose from the plunger cylinĆ
der (1).

" Remove the second plunger cylinder (1) in the same way.
" Unscrew the hexagon nut and remove it from the switching

shaft, and remove the washer.
Note
If the switch lever has a slot, this means that the switch lever is fitted
with clamping bolts, and a pulling bolt is also provided.

123

4 56

WK07_070_1109EN 4

No. 0 Designation
1 Clamping bolts
2 Switch lever
3 Slot
4 Pulling bolt
5 Holes for clamping bolts
6 Nuts for clamping bolts

5ĂĊĂ106 WK07_070_1109EN

Maintenance card
07−070

Page 9 of 16

WK07_070_1109EN 5

Unscrew and remove the clamping bolts if the switch lever is
slotted

" If available, unscrew and remove the clamping bolts (1) from
the switch lever (2).

Note
One of the holes (5) for the clamping bolts (1) is also the pulling bore
for the switch lever (2).
" If required, force the switch lever (2) apart by turning the pulĆ

ling bolt supplied (4) into the pulling bore.
" Pull the switch lever (2) from the switching shaft.

WK07_070_1109EN 5ĂĊĂ107

Maintenance card
07−070

Page 10 of 16

12

3

WK07_070_1109EN 6

No. 0 Designation
1 Fastening bolt
2 Pulling bores (two, diagonally opposite each other)
3 Flanged bearing

" Unscrew the fastening boltĂ(1) from the flanged bearing (3).
" Attach suitable lifting gear to the S transfer tube.
" Press out the flanged bearingĂ(3) by turning the two pulling

bolts supplied into the pulling bores (2).
" Check the gasket set on the flanged bearing for wear, and reĆ

place the gasket set if required.

5ĂĊĂ108 WK07_070_1109EN

Maintenance card
07−070

Page 11 of 16

Replacing the gasket
set in the flanged
bearing

WK07_070_1109EN 7

Removing the retaining ring

" Remove the retaining ring.

WK07_070_1109EN 8

Removing the old grooved ring

" Remove the old gasket set. To do this, you may have to cut
open the rings.

WK07_070_1109EN 5ĂĊĂ109

Maintenance card
07−070

Page 12 of 16

WK07_070_1109EN 9

Inserting the new grooved ring

" Clean the flanged bearing.

" Grease the new gasket set.

Caution
For the mounting position of the grooved ring in the flanged bearing,
please refer to the accompanying spare parts sheet.

" Insert the gasket set.

" If there is a friction bearing bush, check it and replace if
necessary.

" Fit the retaining ring.

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Wear sleeve on
flanged bearing and
collared washer

1 2 34 5

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No. 0 Designation

1 Wear sleeve on the flanged bearing
2 Flanged bearing
3 Collared washer
4 Bore
5 Tab

" Bend the tab (5) on the collared washer (3) downwards.

" Place the collared washer (3) on the flanged bearing (2) so that
the tab (5) is located in the bore (4), thereby securing the
washer against rotation.

" Insert the wear sleeve (1) into the flanged bearing (2).

Note
Note the location of the lubrication bores when fitting the flanged
bearing (2).

" Grease the inside of the wear sleeve (1) with Anti−Seize AS
450 Assembly Paste" or an equivalent assembly grease.

" Locate the complete flanged bearing (2) on the switching shaft
and bolt the flanged bearing (2) in place.

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Mounting the switch 1 2 34 5
lever

76 WK07_070_1109EN 11

No. 0 Designation
1 Switch lever
2 Switching shaft
3 Switching shaft bearing (flanged bearing)
4 Groove
5 Wear sleeve
6 Flattened tooth
7 Notch

" Grease the teeth on the switch lever (1) and the switching shaft
(2) with Anti−Seize AS 450 assembly paste" or equivalent asĆ
sembly grease.

" Fit the switch lever (1) so that the flattened tooth (6) on the
switching shaft (2) sits in the notch (7) on the switch lever (1).

" Fit the switch lever (1) on the switching shaft (2), so that the
switch lever (1) sits in the groove (4) on the wear sleeve (5).

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" Fit the washer to the switching shaft and screw the hexagon
nut onto the switching shaft.

" Lubricate the flanged bearing using the centralized lubrication
system / grease gun.

" Insert the plunger cylinder.

Note
The hydraulic system must be bled once assembly is complete if you
have removed the hydraulic hoses from the plunger cylinders. Do
this by starting up the pump slowly and switching the S transfer tube
across slowly a few times.

" Adjust the S transfer tube so that it switches correctly.
Maintenance card: Adjusting the S transfer tube

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07–071 Replace the spectacle wear This maintenance card describes how to replace the spectacle wear
plate plate. You will find the maintenance intervals in the maintenance
summary at the start of this chapter.

Note
There are specific risks of an accident associated with maintenance,
inspection and repair work. For this reason, read the chapter "Safety
regulations" and the description of the "Residual risks during mainĆ
tenance, inspection and repair work" at the start of the chapter enĆ
titled "Maintenance" (i.e. this chapter).

See also the maintenance cards:
Replacing the transfer tube bearing
Replacing the switching shaft bearing (flanged bearing)
Replacing the thrust ring and wear ring
Adjusting the S transfer tube

You should request the special fitting instructions from us if you have
a spectacle wear plate made from a special material (e.g. hard
metal, hard cast iron, ceramics).

No special tools required.

MA The tightening torques can be found in the corresponding
Spare parts list.

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Danger of crushing
A pressurized hydraulic system may cause the machine to move
suddenly, which may result in you being seriously injured if you are
working on the machine. To avoid risk, shut the machine down and
secure it against unauthorized or accidental starting.

Caution
Use only suitable lifting equipment for lifting components.

Note
Wear parts must be replaced in the event of one of the following:
ć Severe wear is visible
ć Concrete is seeping out

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Shutting down the When maintenance work is carried out, the machine must have been
machine shut down. The operations necessary for this task are described
below and must be carried out conscientiously. Perform all machine
functions using the remote control.

Proceed as follows to shut down the machine:

" Switch off the engine.
" Dump the pressures completely.

Danger
Dump the accumulator pressure completely in systems with pressure
accumulators.

Starting up the The machine may be started up differently depending on the maĆ
machine chine model. When you are starting up a truck−mounted concrete
pump, proceed as follows:

" Unlock the EMERGENCY STOP button and sound the horn.
" Switch the engine on.

Caution
Do not switch the pump on until you are called upon to do so.

When you are starting up a stationary concrete pump, proceed as
follows:

" If there is a throttle, set it to one third.
" Start up the engine.
" Select a low output.
" Switch the pump on.

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