Manual safety regulation_EN

Maintenance card
07−071

Page 4 of 14

Overview

1 23 45 1

66 6

No. 0 Designation WK07_071_1109EN 1
1 Plunger cylinder
2 Switch lever
3 Clamping bolts with nuts
4 Switching shaft
5 Hexagon nut
6 Fastening bolts for spectacle wear plate

5ĂĊĂ118 WK07_071_1109EN

Maintenance card
07−071

Page 5 of 14

Removing the spec- The following describes how to remove the spectacle wear plate.
tacle wear plate
" Shut the machine down.

" Undo the hexagon nut (5) from the switching shaft (4), remove
the plunger cylinder (1) and undo the clamping bolts (3) on the
switch lever (2).
Maintenance card: Replacing the switching shaft bearing
(flanged bearing)

WK07_071_1109EN 2

Pushing the S transfer tube to one side

Note
If there is not enough space available for assembly, you can pull the
pressure connection towards the back.

" Push the S transfer tube away from the spectacle wear plate.

" Undo the eightĂfastening bolts (6) for the spectacle wear plate.
" Remove the spectacle wear plate from the hopper.

WK07_071_1109EN 5ĂĊĂ119

Maintenance card
07−071

Page 6 of 14

Replacing the inter-
mediate rings

1

2

1 23 4 5

WK07_071_1109EN 3

No. 0 Designation

1 Transition liner
2 Intermediate ring
3 Screw plug
4 Lubrication nipples
5 Grease gun

5ĂĊĂ120 WK07_071_1109EN

Maintenance card
07−071

Page 7 of 14

" Using a plastic−faced hammer, strike the old intermediate
ring (2) several times to remove any grout residue that could
block the intermediate ring (2) when it is being removed.

" Replace the screw plug (3) on the underside of the transition
liner (1) using the lubrication nipple (4) from the accessories.

" Connect a grease gun (5) to the lubrication nipple (4).

" Keep pumping in grease until the intermediate ring (2) is
pressed out.

WK07_071_1109EN 4

Leave the bore open

" Remove the lubrication nipple (4) again.
å This will prevent an air cushion from being formed when the
new intermediate ring (2) is inserted, allowing you to insert the
intermediate ring (2) more easily.

" Clean the surface thoroughly. Remove all concrete and grout
residue.

WK07_071_1109EN 5ĂĊĂ121

Maintenance card
07−071

Page 8 of 14

12 3

No. 0 Designation WK07_071_1109EN 5
1 Intermediate ring
2 O−rings
3 Transition liner

" Slide in two O−rings (2) over the mounting surface of the new
intermediate ring (1).

" Grease the mounting surface of the new intermediate ring (1).

" Insert the new intermediate ring (1) into the transition liner (3).

5ĂĊĂ122 WK07_071_1109EN

Maintenance card
07−071

Page 9 of 14

" Using a plastic−faced hammer, tap the intermediate ring (1)
fully into the transition liner (3).

" Replace the second intermediate ring (1) in the same way.

WK07_071_1109EN 6

Fitting the O−ring

" Insert one O−ring (2) into the recess at the front of the interĆ
mediate ring (1).

Fitting the spectacle The following describes how to insert the spectacle wear plate.
wear plate

" Fit the new spectacle wear plate.

WK07_071_1109EN 5ĂĊĂ123

Maintenance card
07−071

Page 10 of 14

11

23

ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ WK07_071_1109EN 7

4 5 67

No. 0 Designation
1 Fastening bolts on the left and right
2 Spectacle wear plate
3 Fastening bolts at the top and bottom
4 Intermediate ring
5 O−ring
6 Hopper wall
7 Clearance

5ĂĊĂ124 WK07_071_1109EN

Maintenance card
07−071

Page 11 of 14

Caution
The spectacle wear plate (2) only touches the O−rings (5) in the inĆ
termediate rings (4). There is a small gap (7) between the spectacle
wear plate (2) and hopper wall (6). For this reason, only tighten the
fastening bolts (1) on the left and right finger−tight at first, because
otherwise the spectacle wear plate (2) will be distorted.

" Fit the new spectacle wear plate (2).
" Using the fastening bolts on the left and right (1), screw on the

new spectacle wear plate (2) finger−tight.

Note
If you have a ceramic spectacle wear plate (2), please contact our
After Sales department to enquire about the tightening torques.

" Using the fastening bolts at the top and bottom (3), screw on
the spectacle wear plate (2) to the appropriate tightening
torque.

Caution
Take care to ensure that the spectacle wear plate (2) does not beĆ
come distorted.

" Using the fastening bolts on the left and right (1), screw on the
spectacle wear plate (2) to the appropriate tightening torque.

WK07_071_1109EN 5ĂĊĂ125

Maintenance card
07−071

Page 12 of 14

WK07_071_1109EN 8

Close the fitting bore

Caution
The fitting bores must be closed to prevent any dirt penetration.

To seal the pulling bores, only use the screw plugs, and not the luĆ
brication nipples. Otherwise, there is a risk that you will accidentally
lubricate these lubrication nipples as well while lubricating the maĆ
chine. Over time, this would push out the intermediate rings, and the
spectacle wear plate would be distorted.

" After inserting the new intermediate rings and spectacle wear
plate, seal the pulling bores again using the screw plugs.

5ĂĊĂ126 WK07_071_1109EN

Maintenance card
07−071

Page 13 of 14

" Replace the thrust ring and wear ring.
Maintenance card: Replacing the thrust ring and wear ring

" Fit the transfer tube bearing.
Maintenance card: Replacing the transfer tube bearing

" Insert the plunger cylinder.
Maintenance card: Replacing the switching shaft bearing

(flanged bearing)
" Adjust the S transfer tube so that it switches correctly.

Maintenance card: Adjusting the S transfer tube

WK07_071_1109EN 5ĂĊĂ127

Maintenance card
07−071

Page 14 of 14

5ĂĊĂ128 WK07_071_1109EN

07–072 Replacing the Maintenance card
S transfer tube 07−072

Page 1 of 8

This maintenance card describes how to replace the S transfer tube.
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 S transfer tube wear sleeve
Replacing the thrust ring and wear ring
Adjusting the S transfer tube
Measuring the wall thickness
Measuring the wall thickness of the double−layer pipe

No special tools required.

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

WK07_072_1109EN 5ĂĊĂ129

Maintenance card
07−072

Page 2 of 8

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

We recommend that the switch lever also be replaced when the S
transfer tube is replaced. Practical experience has shown that the
toothing on the switching shaft and that on the switch lever wear toĆ
gether as a result of the forces generated during switchover. DamĆ
age may be caused by an imprecise fit if only one component is reĆ
placed.

Maintenance card: Replacing the switching shaft bearing
(flanged bearing)

5ĂĊĂ130 WK07_072_1109EN

Maintenance card
07−072

Page 3 of 8

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.

WK07_072_1109EN 5ĂĊĂ131

Maintenance card
07−072

Page 4 of 8

S transfer tube vari-
ants

12

WK07_072_1109EN 1

No. 0 Designation

1 S transfer tube with bolted switching shaft
2 S transfer tube with welded switching shaft

Note
Whichever variant of S transfer tube is fitted, the recommended proĆ
cedure for dismantling is as described below. The S transfer tube
with bolted switching shaft may also be dismantled and reassembled
in the hopper. The tube is then dismantled as described in the S
transfer tube with bolted switching shaft" maintenance card.

You should also consult the Divided hopper" maintenance card if
your machine has a divided hopper.

5ĂĊĂ132 WK07_072_1109EN

Removing the S Maintenance card
transfer tube 07−072

Page 5 of 8

Replace the S transfer tube if the wall thickness has fallen below the
minimum.

Maintenance card: Measuring the wall thickness

Maintenance card: Measuring the wall thickness of the double−
layer pipe

" Shut the machine down.
" Attach suitable lifting gear to the S transfer tube.
" Remove the transfer tube bearing.

Maintenance card: Replacing the transfer tube bearing
" Remove the switching shaft bearing (flanged bearing).

Maintenance card: Replacing the switching shaft bearing
(flanged bearing)

WK07_072_1109EN 2

Removing the mixer shaft

" Remove the mixer shaft.

WK07_072_1109EN 5ĂĊĂ133

Maintenance card
07−072

Page 6 of 8

WK07_072_1109EN 3

Lifting out the S transfer tube

" Unbolt the scratch bar from the bottom of the S transfer tube.

" Push the S transfer tube forwards until the transfer tube outlet
is free.

" Lift the S transfer tube outlet opening first upwards and out.

Note
If just the wear sleeve is heavily worn, you can also replace just the
wear sleeve and then refit the S transfer tube.

Maintenance card: Replacing the wear sleeve on the S transfer
tube

" Fit the new S transfer tube. To do this, proceed in the reverse
order to removal.

5ĂĊĂ134 WK07_072_1109EN

Maintenance card
07−072

Page 7 of 8

" Fit a new thrust ring and a new wear ring.
Maintenance card: Replacing the thrust ring and wear ring

" Fit the switching shaft bearing (flanged bearing).
Maintenance card: Replacing the switching shaft bearing

(flanged bearing)
" Fit the transfer tube bearing.

Maintenance card: Replacing the transfer tube bearing

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

WK07_072_1109EN 5ĂĊĂ135

Maintenance card
07−072

Page 8 of 8

5ĂĊĂ136 WK07_072_1109EN

Maintenance card
07−073

Page 1 of 8

07–073 Replacing the This maintenance card describes how to replace the wear sleeve on
S transfer tube wear sleeve the S transfer tube. 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)

No special tools required.

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

WK07_073_1109EN 5ĂĊĂ137

Maintenance card
07−073

Page 2 of 8

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

5ĂĊĂ138 WK07_073_1109EN

Maintenance card
07−073

Page 3 of 8

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.

WK07_073_1109EN 5ĂĊĂ139

Maintenance card
07−073

Page 4 of 8

Removing the wear If just the wear sleeve is heavily worn, you can replace it without havĆ
sleeve ing to replace the S transfer tube. You do not have to remove the S
transfer tube to do this.

" Shut the machine down.

" Remove the transfer tube bearing.
Maintenance card: Replacing the transfer tube bearing

" Loosen the hexagon nut on the switching shaft and the clampĆ
ing bolts on the switch lever.
Maintenance card: Replacing the switching shaft bearing
(flanged bearing)

Danger
There is a risk of burning during heating and fitting of the new wear
sleeve. Use suitable protective equipment.

5ĂĊĂ140 WK07_073_1109EN

Maintenance card
07−073

Page 5 of 8

1 23 WK07_073_1109EN 1

No. 0 Designation
1 Welds
2 Tube outlet
3 Wear sleeve

Removal when the S If the S transfer tube has been fitted, proceed as follows:
transfer tube is fitted
" Weld a metal pin onto the wear sleeve.

Caution
When cutting open the welds, take care not to damage the S transfer
tube.

" Carefully cut open the welds (1) on the front face between the
S transfer tube outlet (2) and wear sleeve (3) using an angle
grinder.

" Heat up the wear sleeve (3) evenly to approx. 140 °C.

WK07_073_1109EN 5ĂĊĂ141

Maintenance card
07−073

Page 6 of 8

" Using a hammer, strike the metal pin to release the wear
sleeve.

" Remove the wear sleeve (3).

Removal when the S If the S transfer tube has been removed, proceed as follows:
transfer tube has been
removed Caution
When cutting open the welds and wear sleeve, take care not to damĆ
age the S transfer tube.

" Carefully cut open the welds (1) on the front face between the
S transfer tube outlet (2) and wear sleeve (3) using an angle
grinder.

" Heat up the wear sleeve (3) evenly to approx. 140 °C.

" Cut open the wear sleeve carefully using an angle grinder.

" Remove the wear sleeve (3).

5ĂĊĂ142 WK07_073_1109EN

Maintenance card
07−073

Page 7 of 8

Fitting a wear sleeve

12 WK07_073_1109EN 2

No. 0 Designation
1 Wear sleeve
2 Tube outlet

Note
The wear sleeve (1) is chrome−plated, and must not therefore be
heated unevenly or too intensively.

" Heat up the new wear sleeve (1) evenly to approx. 140 _C.

" Place the heated wear sleeve (1) over the tube outlet (2) and
allow the wear sleeve (1) to cool.

" On the front face, evenly position four welds between the wear
sleeve (1) and tube outlet (2).

" Grind the four welds.

WK07_073_1109EN 5ĂĊĂ143

Maintenance card
07−073

Page 8 of 8

" Fit the transfer tube bearing.
Maintenance card: Replacing the transfer tube bearing

" Tighten the hexagon nut on the switching shaft and the clampĆ
ing bolts on the switch lever.
Maintenance card: Replacing the switching shaft bearing
(flanged bearing)

5ĂĊĂ144 WK07_073_1109EN

07–074 Replacing the thrust ring Maintenance card
and wear ring 07−074

Page 1 of 6

This maintenance card describes how to replace the thrust ring and
wear ring on the S transfer tube. You will find the maintenance interĆ
vals 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 spectacle wear plate
Adjusting the S transfer tube

No special tools required.

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

WK07_074_1109EN 5ĂĊĂ145

Maintenance card
07−074

Page 2 of 6

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

5ĂĊĂ146 WK07_074_1109EN

Maintenance card
07−074

Page 3 of 6

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.

WK07_074_1109EN 5ĂĊĂ147

Maintenance card
07−074

Page 4 of 6

Removing the thrust To remove the thrust ring and wear ring, proceed as follows:
ring and wear ring
" Shut the machine down.
" Remove the transfer tube bearing.

Maintenance card: Replacing the transfer tube bearing

" Loosen the hexagon nut on the switching shaft and the clampĆ
ing bolts on the switch lever.
Maintenance card: Replacing the switching shaft bearing
(flanged bearing)

" Inspect the spectacle wear plate and replace it if required.
Maintenance card: Replacing the spectacle wear plate

5ĂĊĂ148 WK07_074_1109EN

Maintenance card
07−074

Page 5 of 6

12

WK07_074_1109EN 1

No. 0 Designation

1 Thrust ring
2 Wear ring

" Remove the old wear ring (2) and the old thrust ring (1).

Fitting the thrust ring To fit the thrust ring and wear ring, proceed as follows:
and wear ring
" Clean the thrust ring seat (1) thoroughly. Dirt and concrete resiĆ
due must be removed from the seat.

" Fit the new thrust ring (1) and new wear ring (2) into the S
transfer tube.

" Fit the transfer tube bearing.
Maintenance card: Replacing the transfer tube bearing

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

WK07_074_1109EN 5ĂĊĂ149

Maintenance card
07−074

Page 6 of 6

5ĂĊĂ150 WK07_074_1109EN

07–075 Adjusting the Maintenance card
S transfer tube 07−075

Page 1 of 14

This maintenance card describes how to adjust the S transfer tube.
This includes:
− prestressing the S transfer tube and
− adjusting the switching overlap between the wear ring and specĆ

tacle wear plate on the S transfer tube.

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 switching shaft bearing (flanged bearing)

No special tools required.

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

WK07_075_1109EN 5ĂĊĂ151

Maintenance card
07−075

Page 2 of 14

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

5ĂĊĂ152 WK07_075_1109EN

Maintenance card
07−075

Page 3 of 14

Shutting down the You will have to shut down and restart the machine a number of
machine times. The operations necessary for this task are described below
and must be carried out conscientiously. Perform all machine funcĆ
tions 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.

WK07_075_1109EN 5ĂĊĂ153

Maintenance card
07−075

Page 4 of 14

Prestressing the S First, prestress the S transfer tube.
transfer tube " Shut the machine down.

5 67 8

9

123 4 WK07_075_1109EN 1

No. 0 Designation

1 Spectacle wear plate
2 Wear ring
3 S transfer tube
4 Thrust ring
5 Gap
6 Hexagon nut
7 Retaining plate
8 Switch lever
9 Clamping bolts

Note
Make sure that the thrust ring (4) is not damaged when it is pressed
in.

" Unscrew the clamping bolts (9) from the switch lever (8).

5ĂĊĂ154 WK07_075_1109EN

Maintenance card
07−075

Page 5 of 14

" Tighten the hexagon nutĂ(6) on the switching shaft so that the
wear ringĂ(2) lies flat against the spectacle wear plateĂ(1).

Note
A gap (5) must be maintained between the S transfer tube (3) and
wear ring (2) so that the S transfer tube (3) switches correctly.

" Check that the wear ring (2) makes contact with the spectacle
wear plate (1) on all sides.

" Slowly tighten the hexagon nutĂ(6) by half a turn.
å The thrust ring (4) is then compressed by 1.5 mm.
å The gap (5) between the S transfer tube (3) and wear
ring (2) is set.

" Ensure that one surface on the hexagon nutĂ(6) is horizontal at
the top so that the retaining plate (7) can be refitted.

" Fit the retaining plate (7).

Note
Use only new nuts for the clamping bolts (9).

" Insert the clamping bolts (9) into the switch lever (8) and fit
new nuts.

" Tighten the clamping bolts (9) to the required torque.
" Further assembly is carried out in the reverse sequence to disĆ

assembly.
Maintenance card: Replacing the switching shaft bearing

(flanged bearing)
" Check that all covers and other safety equipment have been

refitted and are fully functional.

WK07_075_1109EN 5ĂĊĂ155

Maintenance card
07−075

Page 6 of 14

Setting the switching The switching overlap is set to the optimum if the wear ring is central
overlap to the relevant hole in the spectacle wear plate for both switch posiĆ
tions of the S transfer tube. In other words, the swing angle of the S
transfer tube must not be either too great or too small.

Spectacle wear plate
with wear ring

1 2

3

WK07_075_1109EN 2

No. 0 Designation

1 Swing angle too great
2 Swing angle too small
3 Optimum swing angle

The left−hand switching overlap is corrected by replacing the packĆ
ing washer behind the ball cup on the right−hand plunger cylinder
with a thicker or thinner one as required. The right−hand switching
overlap is corrected on the left in the same way.

5ĂĊĂ156 WK07_075_1109EN

12 Maintenance card
07−075

Page 7 of 14

3

WK07_075_1109EN 3

No. 0 Designation
1 Plunger cylinder
2 Ball cup
3 Packing washer

" Start the machine up.

WK07_075_1109EN 4

Plunger cylinder extended

" Allow one plunger cylinder to retract completely.
" Shut the machine down.

WK07_075_1109EN 5ĂĊĂ157

Maintenance card
07−075

Page 8 of 14

1

WK07_075_1109EN 5

No. 0 Designation
1 Marking the spectacle wear plate

" Use a felt tip pen or oil chalk to mark the position of the wear
ring on the spectacle wear plate.

" Start the machine up.
" Allow the other plunger cylinder to retract.
" Shut the machine down.
" Determine to which side and by how many millimetres the

circle you have drawn is offset against the circle of the specĆ
tacle wear plate.

5ĂĊĂ158 WK07_075_1109EN

Spectacle wear plate Maintenance card
with sample markings 07−075

1 Page 9 of 14

2

3

WK07_075_1109EN 6

No. 0 Designation

1 Packing washer too thin
2 Packing washer too thick
3 Optimum packing washer

To decrease the swing angle of the S transfer tube by 4 mm, the
fitted packing washer must be replaced by one which is 2 mm
thicker.
To increase the swing angle of the S transfer tube by 4 mm, the fitted
packing washer must be replaced by one which is 2 mm thinner.

WK07_075_1109EN 5ĂĊĂ159

Maintenance card
07−075

Page 10 of 14

12

WK07_075_1109EN 7

No. 0 Designation
1 Plunger cylinder
2 Locking plate

" Remove the locking plate (2) of the extended plunger cylinĆ
der (1).

10300800

Removing the plunger cylinders

Note
The plunger cylinders can be pushed back as illustrated. It is, howĆ
ever, also possible to screw a bolt into the jacking bores for the ball
cups and to push the plunger cylinders out with the ball cups.

5ĂĊĂ160 WK07_075_1109EN

Maintenance card
07−075

Page 11 of 14

" Force the piston of the extended plunger cylinder back a little
and remove the plunger cylinder with the hydraulic hoses.

12

WK07_075_1109EN 8

No. 0 Designation
1 Ball cup
2 Packing washer

" Remove the hexagon ball cup (1) along with the packing
washer (2).

Caution
No packing washers (2) may be inserted in the switch lever, as otherĆ
wise the plunger cylinder can run over the edge of the ball cup (1)
and break it.

" As required, fit a thicker or thinner packing washer (2) with the
ball cup (1).

" Fit the plunger cylinder and locking plate.
" Start the machine up.

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Page 12 of 14

" Allow the S transfer tube to switch over a few times. Stoppen
Sie, wenn die S−Rohrweiche auf der noch nicht markierten BrilĆ
lenplattenseite steht.

" Shut the machine down.

" Check the switching overlap of the other side of the spectacle
wear plate and correct accordingly.

Switching overlap on The two plunger cylinders must extend to the same extent on maĆ
VHS control chines with fully hydraulic control (VHS) and active signal tapping in
the plunger cylinders.

20300703

Plunger cylinder extended

" First set a switching overlap of the wear ring and the spectacle
wear plate.

" Allow the plunger cylinder (1) to extend to its end position.

" Shut the machine down.

" Measure how far the plunger cylinder has extended. (MeasureĆ
ment E1)

" Start the machine up.

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" Allow the plunger cylinder (2) to extend to its end position.
" Shut the machine down.
" Measure how far the plunger cylinder has extended. (MeasureĆ

ment E2)
" Compare the two measurements.

The two measurements E1 and E2 should be identical. You will have
to change the packing washers as described below if the two
measurements are not equal:

" Swap the packing washer on the plunger cylinder with the
greater measurement for a washer (E1−E2):2 thinner.

" Swap the packing washer on the plunger cylinder with the
smaller measurement for a washer (E1−E2):2 thicker.

Note
This setting must be checked after a running−in period of approxiĆ
mately 100 operating hours.

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10–007 Measuring the wall thick- Maintenance card
ness (Machines with 10−007
S transfer tube)
Page 1 of 6

This maintenance card describes how to measure the wall thickness
of delivery lines. You will find the maintenance intervals in the mainĆ
tenance 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:
Wall thickness measuring device

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

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Note
Delivery lines are subject to constant wear. Measurement of the wall
thickness is particularly important before starting on large jobs.
You will obtain reliable results for your measurements if you carry out
the test with the measuring device recommended by Putzmeister.

Danger of explosion
The delivery line can burst once it reaches a high delivery pressure if
the wall thickness of the delivery line has decreased below the miniĆ
mum required, particularly if a blockage has built up.

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Caution
Only tap the delivery line with a piece of hardwood (hammer handle).
Otherwise, dents may be created and these will lead to more rapid
wear. In addition, the hardened lining of high wear resisting pipes
may flake off the inside of the pipe. The pipe can burst at points that
have suffered heavy wear.

Straight pipes 11000101
Bends
Tapping the delivery line with a hammer handle

Uniform wear can be achieved by regularly rotating the straight deĆ
livery pipes through 120°.
The minimum wall thickness for straight pipes is shown in the graph
below.

Uniform wear can be achieved by regularly rotating the bends
through 180°. The wear on the external radius of a bend is greater
than that on the internal radius or on straight pipes. You should,
therefore, take special care when measuring the wall thickness of the
external radius of a bend.
The minimum wall thickness for bends is shown in the graph below.

11000200

Rotate delivery pipes and bends regularly

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