Operating Instructions

for machine operator and maintenance staff

always keep by the machine

Translation of the original Operating Instructions

Stationary boom MXR 36–4 Multi

Machine no. 180200562

10−11−04

The paper on which this document is printed is 100% chlorine free E Putzmeister Concrete Pumps GmbH 1994
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 de Übersetzung der Originalbetriebsanleitung
bg Ïðåâîä íà îðèãèíàëíî Ðúêîâîäñòâî çà ðàáîòà
cs Pƙeklad originálního návodu k obsluze
da Oversættelse af den originale driftsvejledning
el MetÜfrash tou prwtotýpou twn odhgiþn leitourgßaj
en Translation of the original Operating Instructions
es Traducción de las instrucciones de servicio originales
et Algupärase kasutusjuhendi tõlge
fi Alkuperäisen käyttöohjeen käännös
fr Traduction des instructions de service originales
hr Prijevod izvornika naputka za uporabu
hu Eredeti üzemeltetési útmutató fordítása
it Traduzione delle istruzioni d’uso originali
lt Eksploatavimo instrukcijos originalo vertimas
lv Lietoơanas pamcbas tulkojums no oriinlvalodas
nl Vertaling van de oorspronkelijke gebruiksaanwijzing
no Oversettelse av original brukerhåndbok
pl TƂumaczenie oryginalnej instrukcji eksploatacji
pt Tradução das Instruções de funcionamento originais
ro Traducerea instrucƣiunilor de funcƣionare originale
ru Gthtdjl abhvtzzjuj herjdjlcndf gj ärcgkefnfwbb
sk Preklad originálneho návodu na obsluhu
sl Prevod izvirnih navodil za uporabo
sv Översättning av original instruktionsbok
tr Orijinal kullanűm kűlavuzunun tercümesi

BP00_030_0911EN
 Tableofcontents

Table of contents
1 Guide to the Operating Instructions
1.1 Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 — 1

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

2 Safety regulations
2.1 Definition of terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 1
2.1.1 Concrete pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  1
2.1.2 Boom pedestal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  1
2.1.3 Arm assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  1
2.1.4 Placing boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  1
2.1.5 Base structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  1
2.1.6 Truck mixer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  1
2.1.7 Delivery line systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  1
2.1.8 Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  2
2.1.9 Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  2
2.1.10 Machine operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  2
2.1.11 Hoseman . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  2
2.1.12 Signaller and other auxiliary personnel . . . . . . . . . . . . . . . . . . 2  2
2.1.13 Truck mixer driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  3
2.1.14 Authorized inspector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  3
2.1.15 Subject expert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  3
2.1.16 Qualified personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  3
2.1.17 After Sales Service personnel . . . . . . . . . . . . . . . . . . . . . . . . . . 2  3
2.1.18 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  3
2.1.19 Place of work, working area, danger zone . . . . . . . . . . . . . . . 2  4

2.2 Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 9

2.2.1 Inspection intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  10

2.3 Use contrary to designated use . . . . . . . . . . . . . . . . . . . . . . 2 — 11

2.3.1 Transporting goods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  11
2.3.2 Lifting loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  11
2.3.3 Removing obstacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  11
2.3.4 Extending the reach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  11
2.3.5 Extensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  12
2.3.6 Impermissible endhose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  12

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2.3.7 Impermissible working area . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  12

2.3.8 Climbing the placing boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  13
2.3.9 High−pressure delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  13
2.3.10 Accessories and attachments . . . . . . . . . . . . . . . . . . . . . . . . . 2  13

2.4 Exclusion of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 13

2.5 Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 14
2.5.1 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  14
2.5.2 Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  14
2.5.3 Responsibility of the machine operator . . . . . . . . . . . . . . . . . . 2  14

2.6 Operating Instructions, operating procedures

and other regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 15
2.6.1 Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  15
2.6.2 Operating procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  16
2.6.3 Other regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  16

2.7 Personal protective equipment . . . . . . . . . . . . . . . . . . . . . . . 2 — 17

2.8 Before starting work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 19

2.8.1 Checking that the machine is ready foroperation . . . . . . . . 2  19
2.8.2 Rendering the machine ready foroperation . . . . . . . . . . . . . 2  19

2.9 Danger due to high–voltage . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 21

2.9.1 High−voltage lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  21
2.9.2 Discharge voltage pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  21
2.9.3 Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  21
2.9.4 High−voltage warning devices . . . . . . . . . . . . . . . . . . . . . . . . . 2  23
2.9.5 Procedure in the event of a flash over . . . . . . . . . . . . . . . . . . . 2  23
2.9.6 Earthing in the event of electrostatic charging . . . . . . . . . . . 2  24

2.10 Stationary machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 25

2.10.1 Set−up site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  25
2.10.2 Lifting machines andcomponents . . . . . . . . . . . . . . . . . . . . . . 2  25
2.10.3 Loading and transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  25

2.11 Mobile machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 26

2.11.1 Set−up site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  26
2.11.2 Supporting ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  27
2.11.3 Corner bearing loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  28
2.11.4 Supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  29
2.11.5 Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  30

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2.11.6 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  31
2.11.7 Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  32

2.12 Placing booms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 33

2.12.1 Unfolding the placingboom . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  33
2.12.2 End hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  35
2.12.3 Procedure in storms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  36
2.12.4 Concreting in coldweather . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  36

2.13 Delivery line systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 37

2.13.1 Suitable delivery lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  37
2.13.2 Securing delivery lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  37
2.13.3 Tightness and blockages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  38
2.13.4 Opening delivery lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  39
2.13.5 Clearance to delivery lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  39
2.13.6 Fastening delivery lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  39
2.13.7 Continuation delivery lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  39
2.13.8 Devices for shutting−off, diverting or cleaning delivery lines 2  40

2.14 Pumping operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 41

2.14.1 Place of work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  41
2.14.2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  41
2.14.3 Remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  41
2.14.4 Moving machine components and hotsurfaces . . . . . . . . . . 2  42
2.14.5 Constant observation of the machine . . . . . . . . . . . . . . . . . . . 2  42
2.14.6 Truck mixer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  42

2.15 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 43
2.15.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  43
2.15.2 Cleaning agents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  44
2.15.3 Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  44
2.15.4 Cleaning with compressed air . . . . . . . . . . . . . . . . . . . . . . . . . 2  45
2.15.5 Protection against water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  46
2.15.6 Post−cleaning procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  46

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2.16 Requirements for special work . . . . . . . . . . . . . . . . . . . . . . . 2 — 47

2.17 Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 49

2.18 Working on the placing boom . . . . . . . . . . . . . . . . . . . . . . . . 2 — 50

2.19 Safety–relevant components . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 50

2.20 Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 51

2.21 Protective and safety equipment . . . . . . . . . . . . . . . . . . . . . 2 — 51

2.22 Electrical power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 52

2.22.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  52
2.22.2 Electrical components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  53
2.22.3 Power at the construction site . . . . . . . . . . . . . . . . . . . . . . . . . . 2  53

2.23 Hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 54

2.23.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  54
2.23.2 Replacing hydraulic hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  55

2.24 Noise emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 55

2.25 Exhaust fumes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 56

2.26 Functional fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 56

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3 General technical description

3.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 1

3.2 Description of the functions . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 3

3.2.1 Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  3
3.2.2 Delivery line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  3
3.2.3 Hydraulic control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  3
3.2.4 Climbing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  3

3.3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 4

3.3.1 Hydraulic pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  5
3.3.2 Electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  5
3.3.3 Supply cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  5
3.3.4 Noise emission measurement . . . . . . . . . . . . . . . . . . . . . . . . . . 3  5
3.3.5 Place of work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  5
3.3.6 Machine rating plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  6
3.3.7 Boom rating plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  7
3.3.8 Reaches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  9
3.3.9 Transport frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  10
3.3.10 Slewing circle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  11

3.4 Symbols for the control system . . . . . . . . . . . . . . . . . . . . . . 3 — 13

3.4.1 General symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  13
3.4.2 Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  14

3.5 Electrical control devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 15

3.5.1 Control cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  16
3.5.2 Squeeze valve controlpanel . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  18
3.5.3 Cable remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  19
3.5.4 Chain hoist remotecontrol unit . . . . . . . . . . . . . . . . . . . . . . . . . 3  21
3.5.5 Climbing cylinders remote control unit . . . . . . . . . . . . . . . . . . 3  22
3.5.6 EMERGENCY STOP button . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  23

3.6 Hydraulic control devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 25

3.6.1 Boom functions control block . . . . . . . . . . . . . . . . . . . . . . . . . . 3  26
3.6.2 Climbing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  27

V
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3.7 Other components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 30

3.7.1 Cruciform base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  31
3.7.2 Corner bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  34
3.7.3 Bottom plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  36
3.7.4 Squeeze valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  37
3.7.5 End hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  40
3.7.6 Torque wrench set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  45

VI
 Tableofcontents

4 Transport, assembly and connection

4.1 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 — 1
4.1.1 Lifting points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  2

4.2 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 — 8
4.2.1 Limit parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  9
4.2.2 Fitting the cruciform base on the foundation anchor . . . . . . 4  11
4.2.3 Fitting the cruciform base onto the ballastable cruciform base 4 
18
4.2.4 Assembling the tubular column . . . . . . . . . . . . . . . . . . . . . . . . 4  25
4.2.5 Connecting the tubular column elements . . . . . . . . . . . . . . . . 4  28
4.2.6 Fitting the climbing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  36
4.2.7 Fitting the ladder elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  38
4.2.8 Mounting the workingplatform . . . . . . . . . . . . . . . . . . . . . . . . . 4  39
4.2.9 Fitting the bottom plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  44
4.2.10 Fitting the corner brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  47
4.2.11 Fitting the armassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  49

4.3 Stationary delivery line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 — 59

4.3.1 Danger zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  60
4.3.2 Instructions for layingthe line . . . . . . . . . . . . . . . . . . . . . . . . . . 4  61
4.3.3 Fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  63
4.3.4 SK delivery line system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  67

4.4 Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 — 68
4.4.1 Connecting the delivery line to the boom pedestal . . . . . . . 4  68
4.4.2 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  73
4.4.3 Connecting the cableremote control . . . . . . . . . . . . . . . . . . . 4  76
4.4.4 Connecting the airhose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  79

4.5 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 — 80
4.5.1 Lowering the arm assembly onto the transport frame . . . . . 4  83
4.5.2 Removing the boom pedestal from the tubular column . . . . 4  84
4.5.3 Lowering the boom pedestal onto the transport frame . . . . 4  85
4.5.4 Removing the working platform . . . . . . . . . . . . . . . . . . . . . . . . 4  86
4.5.5 Disassembling the tubular column . . . . . . . . . . . . . . . . . . . . . . 4  87
4.5.6 Removing the ladderelements . . . . . . . . . . . . . . . . . . . . . . . . . 4  90

VII
 Tableofcontents

5 Operation
5.1 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 — 1
5.1.1 Functional fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  1
5.1.2 Function checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  2
5.1.3 Remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  9

5.2 Emergency operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 — 14

5.3 Boom movements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 — 16

5.3.1 Restrictions on use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  17
5.3.2 Danger zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  18
5.3.3 Spontaneous retraction of the boom cylinders . . . . . . . . . . . 5  22
5.3.4 Uncontrolled boom movements . . . . . . . . . . . . . . . . . . . . . . . . 5  23

5.4 Hand signals for boom and pumping operations . . . . . . 5 — 24

5.5 Unfolding the 4 Z boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 — 31

5.5.1 Rest position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  32
5.5.2 Unfolding sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  33
5.5.3 Impermissible working range . . . . . . . . . . . . . . . . . . . . . . . . . . 5  38

5.6 Pumping operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 — 39

5.6.1 Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  40
5.6.2 End hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  42

5.7 Climbing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 — 48
5.7.1 Preconditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  48
5.7.2 Limit parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  52
5.7.3 Before initial climbing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  53
5.7.4 Moving the climbing unit to a floor . . . . . . . . . . . . . . . . . . . . . . 5  58
5.7.5 Climbing procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  66
5.7.6 Terminating the climbing procedure . . . . . . . . . . . . . . . . . . . . 5  69

5.8 Satellite use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 — 73

5.8.1 Different types ofboom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  73
5.8.2 Removing the armassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  74
5.8.3 Moving the arm assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  77
5.8.4 Fitting the arm assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  78

VIII
 Tableofcontents

5.9 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 — 80
5.9.1 Suction cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  81
5.9.2 Tapping
the delivery line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  82
5.9.3 Pressurized water cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  83

5.10 Folding the 4 Z boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 — 85

5.10.1 Folding sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  86
5.10.2 Rest position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  91

6 Maintenance
6.1 Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 1

6.2 General tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 3

6.2.1 Set screws and nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  4
6.2.2 Flared screwed joint, reassembly . . . . . . . . . . . . . . . . . . . . . . . 6  5
6.2.3 Profiled ring joint, reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6  5

6.3 Functional fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 6

6.3.1 Hydraulic fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  6
6.3.2 Level of contaminant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  8
6.3.3 Lubricant analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  8
6.3.4 Storage of lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  8

6.4 Lubricant recommendation . . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 9

6.4.1 Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  11
6.4.2 Greases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  12
6.4.3 Hydraulic fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  13

IX
 Tableofcontents

Maintenance cards
00−001 Visual checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  17
03−001 Changing the hydraulicfluid . . . . . . . . . . . . . . . . . . 6  19
03−002 Function checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  25
04−012 Changing the suction filter element . . . . . . . . . . . . 6  27
04−013 Changing the pressure filter element . . . . . . . . . . 6  33
04−014 Changing the ventilation filter element . . . . . . . . . 6  39
04−002 Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  43
04−005 Vacuum meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6  47
10−005 Measuring the wall thickness
(Machines without transfer tube) . . . . . . . . . . . . . . 6  49
10−044 Measuring the wall thickness of two−layer pipes 6  53
20−062 Lubricating the placing boom (MX 36−4 Multi) . . 6  55
21−015 Lubricating the boom pedestal (MXR) . . . . . . . . . 6  57
25−002 Replacing the delivery line . . . . . . . . . . . . . . . . . . . 6  59

7 Index of key words

Table of contents

8 Glossary
G–1 Symbols for concrete pumps in accordance with
German Mechanical Engineering Association Standard
(VDMA 24119) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G — 1

G–2 Key to the symbols for concrete pumps . . . . . . . . . . . . . . G — 7

G–3 Abbreviations and technical terms . . . . . . . . . . . . . . . . . . . G — 15

X
 1 Guide to the Operating Instructions

In this chapter you will find notes and information that will help you
use these Operating Instructions. Do not hesitate to contact us if you
have any queries:

Putzmeister Condrete Pumps GmbH

After Sales Department
Max−Eyth−Straße 10
D−72631 Aichtal
Germany
Telephone +49 7127 599−0
Telefax +49 7127 599−520
e−mail: services@[Link]

or the Branch or Works Agency that looks after you.

Address:

Telephone:

Telefax:

e−mail:

BP01_001_0802EN
 GuidetotheOperatingInstructions

1.1 Foreword These Operating Instructions are intended to familiarize the user with
the machine and to assist him in using the machine properly in various
operations.

The Operating Instructions contain important information on how to

operate the machine safely, properly and efficiently. Observing these
instructions helps to avoid danger, to reduce repair costs and down

times, and to increase the reliability and service life of the machine.

The Operating Instructions are to be supplemented by the respective

national rules and regulations for accident prevention and environ

mental protection.

The Operating Instructions must always be available wherever the

machine is in use.

These Operating Instructions must be read and applied by any

person in charge of carrying out work with and on the machine e.g.
− operation, including setting up, troubleshooting in the course of
work, evacuation of production waste, care and disposal of fuels
and consumables;
− service (maintenance, inspection, repair), and/or
− transport.

In addition to the Operating Instructions and mandatory rules and

regulations for accident prevention in the country and place of use of
the machine/plant, the generally−recognized rules of technology for
safe and proper working must also be observed.

MX01_004_0802EN 11
 GuidetotheOperatingInstructions

Should you have any questions following your study of the Operating
Instructions, the Branch or Agency serving you, or the Aichtal Works
will be happy to give you more information.

You will make it much easier for us to answer any questions if you
can give us the details of the machine model and the machine
number.

In the interests of constant improvement, modifications are made

from time to time and it could be possible that we were unable to
take these into consideration when these Operating Instructions were
printed.

In the event of any amendment, the copy of the Operating Instruc

tions intended for the machine will be replaced in full.

The reproduction, distribution and utilization of this document as well

as the communication of its contents to others without explicit author

ization is prohibited. Offenders will be held liable for the payment of
damages. All rights reserved in the event of the grant of a patent,
utility model or design.

© Putzmeister Concrete Pumps GmbH 1994

12 MX01_004_0802EN
 GuidetotheOperatingInstructions

1.2 Icons and symbols The following icons and symbols are used in the Operating
Instructions:

" Task symbol

Text following this symbol describes tasks which you are required to
work through from top to bottom in the sequence shown.

å Text following this symbol describes the result or effect of an action.

See also the maintenance cards:

This icon is used to refer to the maintenance cards required,
possibly as a supplement to the maintenance card you are currently
reading.

The following special tools are required:

This icon identifies the special tools necessary to carry out the work.
Normal tools, i.e. commercially−available tools or tools carried in the
truck, are not specially listed.

Environmental protection
Particular specifications regarding environmental protection are
introduced by the icon shown, the words
Environmental protection"
printed in bold, and a line. The associated text is printed in italics
and ends with another line.

Note
Particular information regarding the economic use of the machine is
introduced by the icon shown, the word
Note" printed in bold, and
aline. The associated text is printed in italics and ends with another
line.

Caution
Particular information or rules or prohibitions intended to prevent
damage are introduced by the icon shown, the word
Caution"
printed in bold, and a line. The associated text is printed in italics
and ends with another line.

BP01_003_0601EN 13
 GuidetotheOperatingInstructions

Danger
Particular information or rules or prohibitions intended to prevent
personal injury or significant damage are introduced by the icon
shown, the word
Danger" printed in bold, and a line. The associated
text is printed in italics and ends with another line.

The appropriate icon will be used if it is possible to identify the source

of the danger precisely.

Danger of fire
This icon is used to identify actions for which there is a particular
danger of fire.

Danger of explosion
This icon is used to identify actions during which there is the danger
of an explosion. The explosion may also be caused by pressure
being released suddenly.

Falling items
This icon is used to identify actions in which there is a risk of injury
caused by parts falling down.

Danger of crushing
This icon is used to identify actions during which there is the danger
of being crushed.

14 BP01_003_0601EN
 GuidetotheOperatingInstructions

Suspended load
This icon is used to identify actions in which suspended loads may
fall down.

High voltage
This icon is used to identify actions in which there is the danger of
electrocution, possibly with lethal consequences.

Danger of burning
This icon is used to identify actions in which there is a danger of
burning from chemical substances which are not specifically
described.

Danger of burning
This icon is used to identify actions in which there is a danger of
burning from battery acid.

Danger of poisoning
This icon is used to identify actions in which there is a danger of
poisoning by inhalation of gases, ingestion of or contact with
substances.

BP01_003_0601EN 15
 2 Safety regulations

This chapter corresponds to the contents of the VDMA brochure

entitled

Safety manual Concrete delivery and placing machines".

Here you will find a summary of the most important safety regula

tions. This chapter is, therefore, particularly suitable as an initial
basic instruction for new operators.

Note
Special safety regulations may be necessary for some tasks. These
special safety regulations will only be found in the description of the
particular task.

We include here a listing of regulations and safety standards for your

information:
 EN 12001, Conveying, spraying and placing machines for
concrete and mortar
 EN 12100, Safety of machinery,
 EN 60204−1, Electrical equipment of machines.
 in the Federal Republic of Germany: BGR 182, Betonpumpen und
Verteilermaste

BP03_077_1001EN
 Safetyregulations

2.1 Definition of terms The terms used in this safety manual are explained below, along with
descriptions of the requirements placed on specific groups of
people.

2.1.1 Concrete pump For the purposes of this safety manual, concrete pumps are defined
as devices which are designed to deliver concrete to placement
sites via pipes or hoses.

2.1.2 Boom pedestal In this safety manual, boom pedestal refers to a device for holding
and guiding an arm assembly.

2.1.3 Arm assembly For the purposes of this safety manual, arm assemblies are powered
slewable devices consisting of one or more swinging or folding sec

tions for guiding the delivery line.

2.1.4 Placing boom In this safety manual, placing boom refers to a unit comprising the
arm assembly and boom pedestal.

2.1.5 Base structure For the purposes of this safety manual, base structures are defined
as equipment which is designed to hold a stationary placing boom to
give the latter the required stability.

2.1.6 Truck mixer In this safety manual, truck mixers are vehicles with mixing equip

ment for transporting concrete.

2.1.7 Delivery line systems For the purposes of this safety manual, delivery line systems are de

fined as self−contained pipes or hoses in which concrete is pumped
from the concrete pump to the placement site. Devices for shutting−
off, diverting or cleaning delivery lines can be integrated into delivery
line systems.

BP03_076_1001EN 21
 Safetyregulations

2.1.8 Machine In this safety manual, concrete delivery and placing machines
referto:
− Truck−mounted concrete pumps (ensemble of truck, concrete
pump with and without placing boom). The truck manufacturer’s
safety regulations also apply to the truck.
− Truck mixer concrete pump (an ensemble of truck mixer, concrete
pump and placing boom). The safety regulations issued by the
truck mixer manufacturer and by the truck manufacturer also apply
to truck mixer concrete pumps.
− Stationary concrete pumps
− Stationary placing systems (an ensemble of placing boom and
base structure)

2.1.9 Operator Authorized representative of the owner of the concrete pumps and/or
placing booms. The operator is responsible for the use of these ma

chines.

2.1.10 Machine operator Person trained in and charged with the operation of concrete pumps
and placing booms.

2.1.11 Hoseman Person instructed by the site management in how an end hose is
guided. Hosemen must be able independently to evaluate danger

ous situations which may occur in the area of the end hose and react
according to the situation.

2.1.12 Signaller and other Persons instructed by the site management to help the machine op

auxiliary personnel erator in his work if the latter is unable to observe all areas of oper

ation and danger zones. Signallers must be able to independently
evaluate all dangerous situations which may occur when working
with a concrete pump and/or placing boom, and to react according
to the situation. The signaller must have a suitable means of com

munication with the machine operator.

22 BP03_076_1001EN
 Safetyregulations

2.1.13 Truck mixer driver Person who supplies the concrete pump with concrete from a
truckmixer. Truck mixer drivers must be instructed by the machine
operator to operate the operating elements on the concrete pump
provided for their use. Truck mixer drivers must be able to indepen

dently evaluate all dangerous situations which may occur when
working in the area of the hopper of a concrete pump, and to react
according to the situation.

2.1.14 Authorized inspector Authorized inspectors are persons empowered by the relevant
government bodies to carry out this task of inspection. The prerequi

sites for becoming an authorized inspector are:
− To have completed a higher education course in engineering
orsimilar.
− To have at least 5years’ professional experience in a relevant do

main, of which at least six months must have involved participation
in the work of an authorized inspector.
− To possess thorough knowledge of the relevant health and safety
regulations, as well as of directives and the generally recognised
rules of engineering.
− To have access to the necessary equipment to carry out the
inspection.
− To be able to carry out the tasks impartially.

2.1.15 Subject expert For the purposes of this safety manual, a subject expert is a
personwho, through their professional training, their professional ex

perience and their recent professional activity, has the required
specialist knowledge to inspect the tools.

2.1.16 Qualified personnel Persons who have completed specialist training for a particular activ

ity which qualifies them to carry out their roles.

2.1.17 After Sales Service Qualified persons employed by the manufacturer who are
personnel responsible in particular for maintenance of the machine.

2.1.18 Maintenance Maintenance embraces all measures required for inspection, servic

ing and repair of a machine.

BP03_076_1001EN 23
 Safetyregulations

2.1.19 Place of work, working area, danger zone

Mobile machines
14 6 7
2

1 6

10

3
11

12
5

ab0005

Example

Stationary machines
14 11

4 10

4 9
3

3 6 6 1 2

13
13 13
1
5

11 12

ab0010

Example

24 BP03_076_1001EN
 Safetyregulations

No. 0 Designation Explanation

1 Machine operator In normal operation, with the remote control
2 Place off work
Pl k Hoseman At the end hose in the danger zone
(during
3 Signaller In the machine operator’s range of vision
pumping
4 Auxiliary personnel As manual placing system operators
operations)
5 Truck mixer driver At the hopper in the danger zone
Area with a radius of the reach of the placing boom
6 Permitted
+ end hose length
Working area
The end hose must not be moved backwards
7 Impermissible
beyond the vertical of the placing boom
Risk of injury when pumping is started, during
pumping operations, when removing a blockage
8 At the end hose
and during washing out procedures. The diameter
of the danger zone is twice the end hose length.
Beneath the placing
9 Risk of injury from falling items
boom
Area of the support
legs and feet Danger of crushing when the machine is set up and
10 Danger zone
or area of the base when the supports are retracted
structure
Any presence on or below the machine when the
11 On the machine
pump is in operation is prohibited
Risk of injury during washing out procedures and
12 At the hopper
when the hopper is being filled using a truck mixer
Area of the delivery Risk of lines bursting, risk of injury by crushing or
13
line systems shearing e.g. by gate valves
14 Structure or area being concreted Example

BP03_076_1001EN 25
 Safetyregulations

Place of work The place of work is the area in which people must remain in order to
carry out the work.

Place of work − The machine operator’s place of work is with the remote control when
machine operator the pump is in operation. The place of work must be selected so as
to allow visual contact with the site of concrete placement, and the
truck mixer driver, and so that the working area can be observed at
the same time. A signaller must otherwise be used.

The operator’s place of work is with the machine when this is being
set up or prepared for driving.

Place of work − The hoseman’s place of work is within the danger zone of the end
hoseman hose, but not beneath the placing boom. This requires a greater level
of caution. The hoseman and machine operator must have visual
contact.

Place of work − The truck mixer driver’s place of work is in the danger zone of the
truckmixer driver hopper and at operating elements for the agitator and truck mixer.
This requires a greater level of caution. The truck mixer driver and
machine operator must have visual contact.

Working area The working area is the area in which work is carried out with or on
the machine. Parts of the working area can become danger zones
depending on the operation being carried out and the position of the
placing boom.

The working area must be secured and clearly identified. Suitable

personal protective equipment is required in the working area. The
machine operator is responsible for safety in the working area of the
machine whilst the machine is in use.

Impermissible Because of their high manoeuvrability, some placing booms can also
workingarea be shifted into positions for which they are not designed. This may
overload or damage the placing boom. Placing booms must there

fore only be moved within the permitted working area.

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Danger zone The danger zone is the area surrounding the machine, in which
people may be at risk of injury from movements required by the
work.

The danger zone varies within the working area and depends on the
activity being carried out and the position of the placing boom.
Danger zones must be secured and clearly identified. The machine
operator must be capable of seeing the danger zone at all times and
under all circumstances. If necessary he must appoint a signaller to
supervise the danger zone. Increased caution is called for and suit

able personal protective equipment is required if a place of work is in
a danger zone. The machine operator is responsible for safety in the
danger zone of the machine whilst the machine is in use.

The machine operator must stop work immediately and press the
EMERGENCY STOP button if an unauthorized person enters the
danger zone.

Support legs and There is a danger of crushing in the swing−out and extension zone
support feet for the supports.

Placing boom The danger zone when working with the placing boom is the zone
over which the placing boom is slewed. In this area there is a risk of
injury from falling concrete and delivery line components.

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Machine All the time the vehicle is in operation, there is a risk of injury on and
below the machine from moving parts and bursting delivery lines or
hydraulic hoses, as well as a risk of falling on slippery surfaces or
steps.

End hose The danger zone when pumping is started, during pumping oper

ations, when removing a blockage and during washing out pro

cedures is the area around the end hose in which the hose may
swing out. The diameter of the danger zone is twice the end hose
length.

Hopper In the area of the hopper, there is a risk of becoming trapped

between the truck mixer and the hopper and of being sprayed with
concrete. There is a risk of being crushed and of injury by shearing
from the transfer tube. There is a risk of being entrapped by the ro

tating agitator.

Delivery line systems In the area around the delivery line systems there is a risk of injury
from the delivery line bursting if there is an abrupt rise in pressure.
There is a risk of crushing and injury by shearing with devices inte

grated in delivery line systems.

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2.2 Designated use The machine must only be operated as intended and in technically
perfect condition. All protective and safety−related devices, such as
removable protective devices and EMERGENCY STOP devices,
must be available and fully functional.

The machine is constructed in accordance with the conditions laid

down in the EU Machinery Directive (2006/42/EC) and EN12001.
Nevertheless, its use may constitute a risk to life and limb of the user
or of third parties, or cause damage to the machine and to other
property.

The machine is designed exclusively for the delivery and placing of

concrete up to a bulk density of 2,400 kg/m3. It must only be used for
pumping operations on construction sites. The maximum concrete
pressure must not exceed that specified on the rating plate or in the
check book.

Designated use also includes observing the Operating Instructions

and complying with the intervals and conditions for inspections and
maintenance work.

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2.2.1 Inspection intervals After it is used for the first time, the operational safety of the machine
must be checked regularly by a subject expert. The inspection inter

vals depend on the age of the machine. The older the machine, the
greater the probability of damage. This is why a regular inspection of
the machine, appropriate to its age, is an effective means for the
early detection of damage.

In anticipation of the modification to the EN12001:2003 standard,

the inspection intervals are set as follows:

Machines of up to and including 5years old:

Inspect after every 1,000operating hours or 1year, whichever is
soonest. The interval is repeated after every inspection.

Machines more than 5years old:

Inspect after every 500operating hours or 1year, whichever is
soonest. The interval is repeated after every inspection.

Machines more than 10years old:

Inspect after every 250operating hours or 1year, whichever is
soonest. The interval is repeated after every inspection.

The day of initial commissioning in accordance with the handover

report and the machine’s operating hours meter is definitive for the
intervals. This operating hours meter records the hours of pumping
operations. The operating hours meter must always be kept in good
working order. It must not be tampered with. For machines without an
operating hours meter, the operating hours must be comprehensibly
recorded in writing.

The operator is responsible for commissioning the inspection. The

outcome of the inspections must be recorded in the check book and
confirmed by a signature. The check book must always be kept with
the machine and must be produced upon the request of the national
supervisory bodies.

Notwithstanding national legislation, the operator can be liable in the

event of damage, if it is proved that the damage has arisen as a
consequence of a regular repeat inspection not being properly car

ried out.

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2.3 Use contrary to Any use of the machine which is not described in section 2.2,
designated use entitled Designated use", or which extends beyond the uses
described in this section is deemed to be contrary to designated
use. The manufacturer accepts no liability for damage resulting from
such use. Some examples of conceivable uses that are contrary to
the designated use are given below.

2.3.1 Transporting goods The machine may not be used for the transport of goods, except
forcarrying the accessories used for the machine, such as pipes,
hoses, etc. The maximum permissible gross weight may not be
exceeded.

2.3.2 Lifting loads The placing boom must never be used for lifting loads.

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2.3.3 Removing obstacles The placing boom must not be used under any circumstances to re

move obstacles. This would overload the placing boom, causing
damage and endangering people.

2.3.4 Extending the reach It is prohibited to attach an extension (e.g. freely suspended cross

beam) to the end hose or placing boom tip in order to extend the
reach or to pump at an angle. Since the boom and the lifting equip

ment for the extension have differing pivot points and modes of con

trol, it is not possible to co−ordinate their movements.

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2.3.5 Extensions Extension of the placing boom and end hose beyond the length
specified on the rating plate is forbidden.

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2.3.6 Impermissible The end hose must not be fitted with any extension coupling, spout,
end hose swan neck", outlet shoes or other dangerous outlet fitting or similar
device.

2.3.7 Impermissible The end hose must not be moved backwards beyond the vertical of
working area the placing boom.

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2.3.8 Climbing the placing It is prohibited to climb the placing boom, to stand on top of it or to
boom misuse it as a working platform or aid to climbing.

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2.3.9 High–pressure It is prohibited to deliver concrete at high−pressure (concrete

delivery pressure greater than 85 bar) through the delivery line of the placing
boom. The delivery line and end hose are only suitable forconcrete
pressures up to 85 bar in their new condition.

2.3.10 Accessories and It is prohibited to fit accessories and attachments to the machine
attachments ifthey have not been expressly approved for use on this machine by
the manufacturer.

2.4 Exclusion of liability Where the manufacturer’s delivery conditions are agreed, liability will
be as described in the provisions there. We expressly stipulate that
the manufacturer is not liable for any damage caused in the cases
specified in these conditions.

Unless the responsibility of the manufacturer, the warranty will be in

validated in the following situations in particular:
− use contrary to designated use
− incorrect operation, maintenance and repair
− use of spare parts or accessories other than original manufac

turer’s spare parts and accessories or their equivalents
− conversions, alterations or modifications to the machine
− fitting of accessories and attachments not approved by the manu

facturer
− adjustment of safety pressures, speeds of movement, power
outputs, speeds of rotation and other settings to values other than
those set in the works

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2.5 Personnel The operator must ensure that only persons who are qualified
orhave received the necessary instruction work on or with the
machine. He must clearly define who is responsible for operation
and maintenance of the machine. He must also ensure that only per

sons commissioned to work on the machine do so.

2.5.1 Requirements Persons operating or carrying out maintenance work on the machine
must meet the following requirements:
− They must be aged 18 years or over.
− They must be physically and mentally capable.
− They must be physiologically capable (rested and not under
theinfluence of alcohol, drugs or medication).
− They must have been instructed in the operation and maintenance
of the machine.
− They must have demonstrated their competence to the operator.
− They can be expected to reliably execute the tasks with which
they are charged.

The operating personnel must not wear loose garments or jewellery,

including rings. Long hair which is not tied back must becovered by
a hair net. Injury may result from hair being caught up in the
machinery or from rings catching on moving parts.

2.5.2 Qualifications Do not allow persons who have not yet completed training or instruc

tion, or persons taking a general training course, to operatethe
machine unless under the constant supervision of anexperienced
person.

If you do not have qualified personnel, suitable workshop equipment

etc. available, you should commission the manufacturer’s After Sales
Department with the maintenance of your machine.

2.5.3 Responsibility of the The operator must define the responsibility of the machine operator
machine operator (including in respect to national road traffic regulations) and
empower him to reject instructions from third parties prejudicial to
safety. The machine operator must be able to reject the site of oper

ations if he has doubts regarding technical safety.

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2.6 Operating Instructions, operating procedures and other regulations

2.6.1 Operating Personnel entrusted with work on the machine must have read
Instructions theOperating Instructions, in particular the chapter on safety, before
beginning work. Reading the instructions after work has begun is too
late. This applies especially to persons working only occasionally on
the machine, e.g. during setting up or maintenance.

The Operating Instructions must always be kept to hand at the siteof

use of the machine (in the tool compartment or container provided
for this purpose).

As the operator, you must always make sure that the Operating
Instructions are available. Have personnel working on the machine
confirm in writing their knowledge, understanding and application of
the Operating Instructions and Safety Regulations. At regular inter

vals of at least once a year, check that personnel are conscious
ofsafety and the hazards involved in their work and are taking
account of the Operating Instructions.

Personnel entrusted with work on the machine must observe all

safety notes and hazard warnings.

Personnel entrusted with work on the machine must be familiar with

the machine itself. You must practice all the operating procedures
described in the Operating Instructions (extending the supports, op

erating the placing boom, shifting the placing boom into the driving
position, preparing the vehicle for moving, etc.) under the supervi

sion of a subject expert until you are certain you can execute them
safely. Ask questions if there is something you have not understood.
Begin operating the machine only once you are familiar with the lay

out and significance of all the control and monitoring devices and
the functioning of the machine in general.

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2.6.2 Operating procedures The operator must produce operating procedures for his personnel
in accordance with national regulations. These operating procedures
must include instructions covering the duties involved in supervising
and notifying special organisational features, e.g. organization of
work, working procedures or the personnel entrusted with the work.
Furthermore, reference must be made to other generally valid legal
and otherwise mandatory regulations relating to accident prevention
and environmental protection. Such regulations may also deal with
handling hazardous substances, the issuing and wearing of personal
protective equipment or with national road traffic regulations. You
should familiarise yourself with the site of operations and with how to
use fire extinguishers. Observe the fire−alarm and firefighting pro

cedures.

2.6.3 Other regulations The current regulations for concrete delivery and placing machines
as issued by:
− the legal authorities in your country
− national supervisory bodies
− the responsible commercial liability insurance company
are binding on the operator of the machine.

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2.7 Personal protective In order to reduce risks to personnel, personal protective equipment
equipment must be used in so far as this is necessary or deemed to be so by
regulations. All personnel working on or with the machine must wear
safety helmets, protective gloves and safety shoes.

Personal protective equipment must, as a minimum, comply with the

requirements of the specified standards.

Safety helmet
A safety helmet protects your head against, for instance, falling
concrete or parts of the delivery line in the event of a hose bursting.
(ENISO397; Industrial safety helmets)

Safety shoes
Safety shoes protect your feet against falling objects and against
penetration by projecting nails.
(ENISO345; Safety shoes for professional use; ClassS2)

Hearing protectors
Hearing protectors protect you against the noise generated by the
machine when you are standing close to it.
(ENISO352−1; Hearing protectors − General requirements − Part1:
Earmuffs
or
ENISO352−3; Hearing protectors − General requirements − Part3:
Earmuffs attached to an industrial safety helmet)

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Protective gloves
Protective gloves protect your hands against aggressive or chemi

cal substances, as well as against mechanical effects (e.g. impact)
and cutting injuries.
(ENISO388; Protective gloves against mechanical risks;
Class1111)

Protective goggles
Protective goggles protect your eyes against injuries from concrete
spatters or other particles.
(ENISO166; Personal eye−protection − Specifications)

Safety harness
When working at height, use the climbing aids and working plat

forms provided for reasons of safety or wear a safety harness.
Therelevant national regulations must be complied with.
(ENISO361; Protective Equipment Against Falls from a Height −
Full Body Harnesses; CategoryIII)

Face mask and respiratory protector

A face mask and respiratory protector protect you against particles
of building materials which could enter your body through your res

piratory passages (e.g. concrete admixtures).
(ENISO149; Respiratory protective devices − Filtering half masks
to protect against particles − Requirements, testing, marking;
ClassFFP1)

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2.8 Before starting work

2.8.1 Checking that the As machine operator, it is your responsibility to check the machine
machine is ready for external damage and defects before any use of the machine. You
for operation must immediately report any changes (including changes in the
working characteristics) to the organization or person responsible. If
necessary, shut the machine down and secure it against use.

2.8.2 Rendering the As machine operator, you are responsible for rendering the machine
machine ready ready for operation. This also includes topping up the functional
for operation fluids. Do not fill with fuel in enclosed spaces. Switch off the engine
and the heating. Wipe up spilt fuel immediately. Do not smoke or use
a naked flame when handling fuel.

Set all the control and monitoring devices to the zero position before
you change the mode of control (control block, control console or
remote control). Press the EMERGENCY STOP button. otherwise the
machine might execute unintended movements.

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Never put the remote control down when the machine is ready
foroperation. If this is unavoidable in exceptional cases, you must
press the EMERGENCY STOP button, disconnect the remote control
and lock the remote control away (see also page241).

Never leave the machine when the engine is running or when the en

gine could be started by an unauthorized person. If you need
toleave the machine, proceed as follows:
− press the EMERGENCY STOP button,
− disconnect the remote control and lock it away,
− switch off the ignition or the main switch,
− lock the control cabinet.

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2.9 Danger due to high–voltage

2.9.1 High–voltage lines Whenever you touch a high−voltage line, there is a risk of death
forall persons either on the machine or in its vicinity or who are con

nected to it (via the remote control, end hose, etc.). A spark can
jump across from a high−voltage line even if you just approach it and
this will energize the machine and the surrounding area.

2.9.2 Discharge voltage In the event of a flash over, what is known as a discharge voltage
pattern pattern" is formed in the vicinity of the machine. The voltage
decreases from the inside to the outside in this discharge voltage
pattern. If you step within this discharge voltage pattern, you will
bridge different potentials. This will cause a voltage corresponding to
the potential difference to flow through your body.

2.9.3 Clearances Maintain a minimum clearance from high−voltage lines in accord

ance with the following table. The minimum clearance is measured in
the horizontal when the placing boom is fully extended.

Rated voltage [V] Minimum clearance [m]

up to 1 kV 1.0

1 kV to 110 kV 3.0

110 kV to 220 kV 4.0

220 kV to 380 kV 5.0

unknown rated voltage 5.0

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The specified clearances are minimum requirements. You must ob

serve any greater clearances that may be specified in the country of
use.

When you set a minimum clearance, the possibility of the high−

voltage lines and the placing boom swaying in the wind must also be
taken into consideration. You should further note that where air hu

midity is high, clearances greater than the minimum clearances
shown above are always necessary.

You must stand as close as possible to the unfolded placing boom if

you wish to estimate correctly the movements of the boom and,
above all, the clearance between the placing boom and obstacles or
high−voltage lines.

The same minimum clearances are necessary when driving under

overhead cables.

In the event that this minimum clearance cannot be maintained

under all possible working positions, the power station responsible
must be contacted and you must have the high−voltage line
switched off.

Should you have any doubts, it is better to forego the use of the plac

ing boom and to lay a separate delivery line, for instance.

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2.9.4 High–voltage warning According to the current rules of engineering, high−voltage warning
devices devices do not meet a safety standard which enables a safe under

shooting of the required minimum clearances to high−voltage lines.
Previous experience has shown that high−voltage warning devices
cannot make all situations in working procedures safe. Flash overs
and fatal accidents can occur despite the use of a high−voltage
warning device. You must therefore always maintain the minimum
clearances mentioned above.

2.9.5 Procedure in the Should a flash over occur, despite all precautions, stay calm, do not
event of a flash over move (potential differential), touch nothing.

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If your machine comes into contact with heavy current lines:

− Warn those outside against approaching and touching the
machine.
− Have the power switched off.
− Only leave the machine once you are sure that the line you
havetouched or damaged has been de−energized.

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Power stations are always equipped with automatic switch−on

devices. If a circuit breaker trips, the short−circuited cable will be
switched back on again after a brief interval. Brief intervals when the
voltage is absent give rise to a false sense of safety.

You should only move and rescue injured persons once a represen

tative of the power station has notified you that the cable has been
switched off.

A radio remote control system only protects the machine operator

ifhe is standing outside the discharge voltage pattern.

2.9.6 Earthing in the event Faults can be caused in the radio remote control system and
of electrostatic dangerous electrical charging of the machine can occur when work

charging ing in the vicinity of transmitters (radio transmitter, etc.). Persons who
bridge the charged parts to the earth are heavily charged on con

tact.

Machines in use in the vicinity of transmitters must be earthed.

Secure the earthing cable (at least 16mm2) to an extra pre−pre

pared, bright metal point of the machine (e.g. not to a piston rod)
and to a conductive metal rod in the ground (minimum insertion
depth of 1.5m). Thoroughly dampen the earth around the metal rod
to make it more conductive.

Even when the machine is earthed, the safe clearances to high−volt

age lines (see page 221) must be maintained and the instruc

tions regarding storms and bad weather (see page 236) must be
observed.

If you have any further questions about earthing the machine, please
contact the construction site management or the operating company
of the machine.

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2.10 Stationary machines

2.10.1 Set–up site Stationary machines are generally used on a construction site for
alengthy period. For this reason, site management should prepare
the set−up site carefully. The site management must deliver the
necessary documents in good time in order to be able to prepare the
foundations, base plates or similar on time.

When selecting the set−up site, remember that the machine must be
dismantled and transported away again at the end of its use on site.
The ambient conditions may change as construction work prog

resses.

2.10.2 Lifting machines Machines which are transported to the set−up site in individual parts
and components or not under their own power must only be lifted with suitable lifting
equipment in accordance with the specifications in the Operating
Instructions. The lifting gear on the machine must be capable of ac

cepting the lifting gear and lifting the load. No−one should stand
under suspended loads. Before work is started, a subject expert
must check that the assembled machine is working properly.

2.10.3 Loading and Only use suitable means to load and transport stationary machines.
transporting Ensure that no−one can be injured by the machine tipping over or
slipping.

If there are fixtures provided for transport of the machine or its indi

vidual components, only these should be used. The machine or
components must be properly lashed down during transport. The
transport vehicle and machine must be marked to conform with the
road traffic regulations in the country concerned if they are to use the
public highway.

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2.11 Mobile machines

2.11.1 Set–up site It is the machine operator who takes responsibility for setting up
themachine 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 obstacles in the work and travelling areas, the
loadbearing capacity of the supporting ground and any barriers sep

arating the construction site from public roads.

You must also check the approach route to the site where the ma

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 into thesite
where the machine will be set up. If necessary, have the approach
route closed off or secured by signallers. Have any materials or
equipment that hinder your approach removed.

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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.

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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, con

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 sup

port timbers must be undamaged and free from ice, oil, grease, etc.
The support blocks and timber blocks must be laid under the sup

port plates such that the load is distributed uniformly and the sup

port leg cannot slip off the side of the support.

Check the stability of the machine regularly during operation.

Interrupt the pumping operation if the machine becomes unstable.
Factors which reduce stability include, for instance:
− modifications to the ground conditions, e.g. caused by rain water
or the thawing of frozen ground
− the support sinking on one side
− fluid losses through leaks in the support hydraulics

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

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The force transferred to the ground by each support leg diffuses

through the soil in a conical pattern at an angle of 45_. Safe
clearance to the pits and slopes must be maintained, and such
clearance must be determined in accordance with the nature of
theground. 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 2m.

For loose or back−filled ground, the safe clearance is twice the pit
depth, but a minimum of 2m.

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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
insequence. Intermediate positions are prohibited to guarantee sta

bility.

Lock all supports mechanically, if this is provided for in the design.

Close all shut−off valves in the support hydraulics. Leaks can cause
the supports to sink on one side.

The machine must be made level in all directions. The maximum per

mitted deviation from the horizontal is 3_. Greater deviations from the
horizontal overload the slewing gear for the placing boom and jeop

ardize the stability of the machine.

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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.

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2.11.5 Driving When preparing the machine for driving, you must perform the
following 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 se

cured.
− Raised or locked axles must be lowered and released.
− Accessories belonging to the machine must be safely stowed
away and 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 driv

ing style to the altered centre of gravity of the machine. You must not
exceed the maximum permissible gross weight of the machine. Ob

serve the road traffic regulations and specifications of the machine
manufacturer.

Maintain a clearance of at least 1m from the secured edges of con

struction pits and at least 2m from slopes.

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Always make sure that there is sufficient clearance when driving

under underpasses, over bridges and through tunnels or when pas

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 ca

pacity is adequate.

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Do not drive across uphill or downhill gradients. Be aware of the el

evated position of the truck’s centre of gravity when travelling ona
slope and on ascending or descending routes. Always adapt
yourtravelling 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 speci

fied in the Operating Instructions. The truck is at risk of tipping over,
particularly when travelling round corners.

2.11.6 Towing The machine must only be towed, loaded and transported in accord

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.

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2.11.7 Loading The lifting points fitted to the machine as standard are provided
forassembly purposes only. They are not suitable for lifting the com

plete machine. The lifting points for lifting the entire machine are
specially marked.

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Use only appropriate means of transport and lifting equipment of ad

equate loadbearing capacity. Lifting equipment, lifting tackle, sup

port trestles and other auxiliary equipment must be reliable andsafe
in operation.

Use only stable loading ramps of adequate loadbearing capacity

forloading. 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.

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2.12 Placing booms

2.12.1 Unfolding the Only raise a mobile placing boom from the driving position once
placing boom themachine has been supported in accordance with the Operating
Instructions. 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 Oper

ating Instructions. The correct sequence depends on the folding sys

tem (roll−and−fold system, Z−fold system, etc.).

Always ask the site management to supply 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.

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

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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.

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Placing booms with placing boom hinges which allow considerable

flex angles have a very large potential working area. Because of this
high manoeuvrability, various placing booms can, however, also be
shifted into positions that are of no interest for the pumping oper

ation. Under certain circumstances it is even possible to overload or
cause damage to the placing boom. We have indicated such imper

missible working areas by the use of warning signs and information
plates on the machine and appropriate notes in the Operating In

structions.

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2.12.2 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. No−one 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.

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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 boom.

Never bend the end hose over. Never attempt to straighten a bent
end hose by increasing the pressure. The end hose must not be sub

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 always be filled with concrete as far as the agitator shaft so that
no air can be sucked in.

The end hose must be secured against falling.

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2.12.3 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 42m or more may only be
operated in wind forces up to7 (wind speed61km/h=17m/s).
− Placing booms with a vertical reach of less than 42m may only be
operated in wind forces up to8 (wind speed74km/h=20m/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.

Tower cranes on construction sites generally have wind speed

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 force7 and greater, green leaves break from the trees
and there is perceptible resistance when walking against the wind.
− In winds of force8 and greater, small branches break from trees
and walking outside is significantly impeded.

2.12.4 Concreting in The boom must not be used in temperatures below minus 15_C
cold weather (+5_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 real

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.

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2.13 Delivery line systems

2.13.1 Suitable delivery lines Use only perfect delivery lines, end hoses, couplings, etc. suitable
for the delivery job and manufactured by the machine manufacturer.
Delivery lines are subject to wear which varies according to the pres

sure 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 se

lines curely fastened and secured against spontaneous opening.

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2.13.3 Tightness and Regularly force water through the delivery line under operating pres

blockages sure to check that the system is watertight.

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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. Always try to remove the blockage
by reverse pumping and then restarting forward pumping. If the
blockage is not removed, relieve the pressure on the delivery line
before removing the section of delivery line concerned.

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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. Theconcrete col

umn must be depressurized by reverse pumping before the delivery
line is opened. Never work bending directly over the coupling.

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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 deliv

ery line must be covered by suitable means.

2.13.6 Fastening delivery Delivery lines, in particular riser lines which are not laid along
lines placing 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.

2.13.7 Continuation delivery A continuation delivery line connected to the placing boom must not
lines exert a load on the boom.

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2.13.8 Devices for shutting– During operation there is a risk of being crushed and of injury by
off, diverting or shearing. Hydraulically driven devices are generally supplied with
cleaning delivery lines power by a machine’s hydraulic system. It must therefore be
possible to see from the devices and the machine with control unit
and vice versa. Observe the safety regulations for the machine and
the device 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.

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2.14 Pumping operations

2.14.1 Place of work The machine operator’s place of work is with the remote control when
the pump is in operation. If you operate the machine using the re

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 equip

ment are only provided for assembly and maintenance work. Use of
these platforms as a workplace during operation is prohibited.

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.

2.14.2 Safety Before switching on the machine, you must make sure that nobody
can be injured by the running machine.

Refrain from any procedures that may impair the stability of the
machine or are prejudicial to safety in any other way.

2.14.3 Remote control You must always carry the remote control on your person when
themachine is ready for operation. Only in this way can it be guaran

teed that you can press the EMERGENCY STOP button inthe event
of an emergency situation. The EMERGENCY STOP button may only
be unlocked once the cause/emergency has been remedied (see
also page220).

You must carry the remote control in such a way that no control
element is actuated unintentionally.

During breaks in pumping, interruptions, maintenance work or your

absence from the machine, you must secure the machine against
inadvertently rolling away and to prevent unauthorized use. Press the
EMERGENCY STOP button on the remote control and lock the re

mote control away.

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2.14.4 Moving machine Keep all access covers, maintenance flaps, guards, etc. closed
components and andlocked during operation. This also applies to the grille, water
hot surfaces box cover, and covers on cylinders, for example. There is otherwise
a risk of injury from moving parts of the machine and a risk of bur

ning 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 other

wise secured.

Do not touch moving parts of the machine, whether the machine

isrunning 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
of the machine orfaults while it is in use. In the event of faults or malfunctions that
impair 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 delivering the concrete to you. 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.

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2.15 Cleaning

2.15.1 General You must drain the delivery line, pump and hopper completely. Con

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
orthe 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.

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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
flowing 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.

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 Safetyregulations

2.15.2 Cleaning agents Take care when using aggressive cleaning agents. Aggressive clea

ning agents may attack materials (e.g. rubber) and painted surfaces.
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 manu

facturer of the cleaning agent to confirm its suitability. Observe the
manufacturer’s instructions regarding use and safe handling. Wear
protective clothing. Always rinse off cleaning agent thoroughly with
clean water; do not allow puddles to form.

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Do not use sea water or other water containing salt for cleaning pur

poses.

Do not use any highly flammable agent for cleaning; there is a

danger of fire.

2.15.3 Hazards 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 compo

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.

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2.15.4 Cleaning with When the delivery line is being cleaned with compressed air, thereis
compressed 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 regulations.

The manufacturer accepts no liability for damage caused by

incorrectly performed compressed air cleaning. If you blow out the
delivery line with compressed air, you must observe the following
rules without fail:
− Individual pipes and short pipe runs up to 10m 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
diameter 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 deliv

ery line.
− No persons may be present in an area of 3m 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 ex

pelled from the catch basket cannot injure anybody or cause any
damage.

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 Safetyregulations

− The wash−out adaptor must be fitted with a separate, large dump

cock and a pressure gauge.
− The pressure gauge must be kept under constant observation dur

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 (e.g.open the delivery line) once
this has been depressurized. Make sure that the compressed 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.

2.15.5 Protection against Water spraying on the machine from random directions has no dam

water 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
cabinets are particularly at risk.

2.15.6 Post–cleaning After the machine is cleaned, the covers/tapes must be completely
procedure removed and the machine must be checked to ensure that it is ready
for operation (see also page219).

Look out for leaks, loose connections, chafe marks and damage dur

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.

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2.16 Requirements for In the capacity of operator, it is your responsibility to provide all the
special work necessary information to the personnel concerned before special
work or maintenance work is carried out. Someone should be nomi

nated as the person responsible for this.

Carry out the maintenance and inspection operations and comply

with intervals specified in the Operating Instructions, including spec

ifications for the replacement of parts and equipment. These acti

vities must be carried out by qualified personnel only.

Workshop equipment appropriate to the task in hand is absolutely

necessary for the execution of maintenance work.

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

necessary.

A machine completely shut down for maintenance and repair work

must be secured against being restarted inadvertently:
− Lock the main control devices and remove the key.
− Fix a warning plate to the main switch.

Only carry out maintenance work if the machine is parked on level

and sufficiently supporting ground and is secured against rolling
away.

Use specially designed or otherwise safety−oriented climbing aids

and working platforms when carrying out assembly work above head
height. Never use machine parts as climbing aids. Keep all hand

grips, steps, railings, platforms and ladders free from dirt, snow and
ice.

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 Safetyregulations

Carefully secure individual parts and large assemblies to lifting gear

when carrying out a replacement operation. Use only suitable and
technically perfect lifting gear and suspension systems with ad

equate lifting capacity. Never stand under suspended loads.

The fastening of loads and instruction of crane operators should be

entrusted to experienced persons only. The signaller must be within
visual range of or in voice contact with the crane operator.

Observe national regulations when working with lifting gear.

Work on chassis, braking and steering systems must only be carried

out by qualified personnel trained for such work.

Clean the machine, especially connections and threaded unions,

ofany traces of oil, fuel or preservatives before carrying out mainten

ance or repair work. Do not use aggressive cleaning agents. Use
lint−free cleaning rags.

Bolted connections that you have loosened for carrying out mainten

ance and repair work must always be retightened to the specified
torque.

Do not open gas−filled spring elements, as used on maintenance

flaps, for instance. The spring elements are filled with gas under high
pressure which can escape explosively if you attempt to open them.
Relieve the tension on systems under mechanical stress.

Be aware of hot functional fluids and surfaces (hydraulic fluid,

hydraulic fluid radiator, etc.).

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

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2.17 Welding Only qualified personnel commissioned by the manufacturer may

carry out welding work on the placing boom, on the supports or on
other components which are important for safe operation. The work
must be inspected by an authorized inspector.

Always attach the earth cable and welding machine directly to the
component that is to be welded. The welding current must not flow
through hinges, cylinders, etc. Significant damage may be caused
by current bridging gaps.

Electronic components can be destroyed by stray voltage during arc

welding processes. For this reason:
− Disconnect the remote control cable from the control console.
− Disconnect all cables leading to the receiver of the radio remote
control system.
− Close connector sockets with caps.
− Disconnect the positive and negative leads from the battery.

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

Clean the machine and its surroundings of dust and flammable sub

stances and make sure that the premises are adequately ventilated
before carrying out welding, flame−cutting and grinding operations
(danger of explosion).

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

tions.

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2.18 Working on the Only carry out maintenance and repair work on the placing boom
placing boom ifthe placing boom is folded or properly supported, the engine is
switched off and the support legs are secured.

Support the placing boom arms before starting work on the valves,
cylinders or hydraulic lines on the boom.

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

Following substantial changes, placing booms must be inspected by

an authorized inspector before recommissioning.

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

Parts relevant to safety and adjustable devices (pressure limiting

valve, potentiometer, fluid flow limiter, hydraulic cylinders, etc.) must
only be repaired, replaced or adjusted by After Sales Service per

sonnel. Seals must only be removed by the manufacturer’s After
Sales Service personnel. Modifications to the machine ratings (for
example, increasing pressures, modifying speeds, etc.) are not per

mitted.

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

Only persons authorized by the machine manufacturer may inter

vene in the machine’s software. This also applies to updates.

Unauthorized interventions in the machine’s software may lead to se

vere damage and accidents.

2.21 Protective and safety Any safety devices removed for maintenance purposes must be re

equipment fitted and checked immediately upon completion of this work.

All equipment required for safety and accident prevention (warning

signs and information plates, grilles, guards, etc.) must be in place.
Such equipment must not be removed, modified or damaged.

Keep all warning signs and information plates on the machine

complete and in a perfectly legible condition.

It is your responsibility as operator to ensure that any warning

signsand information plates that have been damaged or rendered
illegible are replaced without delay.

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2.22 Electrical power

2.22.1 General Work on electrical systems or operating equipment must only be car

ried out by qualified personnel. For further information on machines
operated on the site power supply, see also section2.22.3, entitled
Power at the construction site".

The power supply to machine components on which maintenance

work is to be carried out must be isolated, if provided for in the re

gulations. Before starting any work, you must check the de−ener

gized parts for the presence of power and earth or short−circuit them
in addition to insulating adjacent live parts and elements. Disconnect
the negative lead from the battery before starting any work on the
electrical system. When reconnecting, connect the positive terminal
first, and then the negative terminal.

Before starting work on high−voltage assemblies and after cutting

the power supply, you must connect the supply cable to earth and
short−circuit the components such as capacitors with a rod−type
earth electrode.

If work is to be carried out on live parts, the presence of a second

person is required who can switch off the power supply to the ma

chine in the event of an emergency. Secure the working area with
ared−and−white safety chain and a warning plate. Use insulated
tools only.

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2.22.2 Electrical components Control cabinet, motor and control elements are protected as
standard at least to degree of protection IP54. IP54 means:
− Complete protection against contact with live components orinter

nal moving parts. Protection against damaging dust deposits.
− Water spraying on the equipment from random directions shallnot
have a damaging effect.

Use only original fuses with the specified current rating. The electri

cal system can be destroyed by overrated fuses or bridging. You
must switch off the machine immediately if a fault occurs in the
power supply.

2.22.3 Power at the The power on the construction site must be supplied from a special
construction site feed point (construction site power distribution point). Machines with
an electric motor must not be connected to the mains power supply.

Only qualified personnel may work on electrical systems with anop

erating voltage in excess of 25volts alternating voltage or 60volts
direct current. Only such qualified personnel may install, connect,
disconnect and open electrical control cabinets.

An electric shock (possibly with fatal consequences) may be the re

sult of touching machines with electric motors or contact with other
electrical cables if the electrical connection has not been made
properly or the supply cable is damaged.

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2.23 Hydraulic systems

2.23.1 General Work on hydraulic systems must only be carried out by qualified per

sonnel.

Always wear your personal protective equipment when carrying

outwork on the hydraulic system. Escaping fluid is toxic and can
penetrate the skin.

Injection through the skin is a major medical emergency situation. In

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

Parts of the system and pressure lines which are to be opened

(hydraulic, pneumatic, and delivery lines) must be depressurized
according to assembly descriptions before repair work is started.

Work only on depressurized systems. Switch the hydraulic pump

drive and the engine off, otherwise there is a risk of injury caused by
functional fluids escaping under pressure. Where a hydraulic accu

mulator is fitted, open the accumulator dump valve to prevent any
movements of the machine as a result of the residual pressure.
Modifications to the hydraulic accumulator are prohibited.

Be aware that enclosed hydraulic fluid can remain under pressure

for a certain length of time. Do not open any hydraulic systems if
they are under pressure from an external force (e.g. from a raised
placing boom).

Route and install hydraulic lines in accordance with current engin

eering standards. Ensure that connections are not interchanged. The
fittings, lengths and quality of the hoses must comply with technical
requirements.

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You must carefully bleed the hydraulic system after any maintenance
work, otherwise there is a risk of injury caused by swinging and tele

scopic support legs extending rapidly, the placing boom lowering,
etc. Open vent valves very carefully until hydraulic fluid starts to es

cape. You should on no account open vent valves further than
necessary or go so far as to remove them.

Damaged hydraulic lines must be replaced rather than repaired. You

must replace damaged or saturated hydraulic hoses immediately.
Spurting hydraulic fluid may cause injury and fire.

2.23.2 Replacing hydraulic During the repeat inspections, a subject expert must check the
hoses hydraulic hoses for external damage. The inspection must be
recorded in the check book. The operator must have hydraulic hoses
replaced if they show signs of external damage.

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

Wear suitable personal protective equipment in the vicinity of the ma

chine.

As the operator, you must instruct your personnel to always wear

their personal ear protection. You are responsible for ensuring that
your personnel comply with this regulation.

All soundproofing equipment must be fitted and in perfect condition.

All soundproofing equipment must be closed during operation.
Ahigh sound level can cause permanent hearing damage.

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2.25 Exhaust fumes Vehicle exhaust gases contain constituents which can be lethal or
carcinogenic. Operate internal combustion engines and fuel−oper

ated heating systems only in adequately ventilated premises. Before
starting up the engine in enclosed spaces, make sure that there is
adequate ventilation and direct the exhaust gases away from the
place of work.

Wear personal protective clothing and equipment for all work in

which exhaust gases or particles of building material can enter the
body through the respiratory passages. Comply with the information
issued by the manufacturer of the building material.

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

Oils, fuel and other functional fluids may be hazardous to health

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

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Take care when handling toxic and caustic functional fluids (brake
fluid, battery acid, water glass, concrete set accelerating admix

tures, cement, etc.). Building materials containing cement have a
highly alkaline effect when they react with water (and also with
perspiration). Admixtures are toxic and caustic.

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Cleaning agents, concrete release agents, preserving agents etc.

propelled by compressed air can cause very serious damage to the
respiratory tract if a respiratory protection mask is not worn. Spray
mist enters the lungs very easily.

Frequent injuries are eye injuries caused by concrete spatter, water

glass or other chemical substances.

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

Have used operating equipment and functional fluids such as filters,

batteries, oil, brake fluid, etc. disposed of properly. Used cleaning
rags should also be disposed of properly.

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 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
 Generaltechnicaldescription

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

12 13

11

10

8
16 15 14
7

18

19
5 28

17
21
22

4 20

23 26
24
2
23 25
1 23 27

MX02_377_0811EN 1

MX02_377_0811EN 31
 Generaltechnicaldescription

No. 0 Component Page

1 Bottom plates 336
2 Climbing column 34
3 Tubular column 34
4 Corner brackets 334
5 Climbing system 327
6 Working platform 34
7 Boom pedestal, with or without quick disconnect point 33
8 Chain hoist control cabinet LEERERMERKER
9 Control cabinet 316
10 Hydraulic pack with electric motor 35
11 Boom rating plate 33
12 Arm assembly lifting tackle
13 Arm assembly, with or without quick disconnect point 34
14 Squeeze valve 337
15 Boom control block (left−hand side) 326
16 Machine rating plate 36
17 Ladder element with protection 34
18 Climbing system remote control 321
19 Cable remote control 319
20 Boom pedestal transport frame 310
21 Arm assembly transport frame 310
22 Arm assembly transport trestle 310
23 Cruciform base, compact 34
24 Cruciform base for tie rods 34
25 Set of tie rods 34
26 Ballastable cruciform base 34
27 Foundation anchor 34
28 Documentation accompanying the machine

32 MX02_377_0811EN
 Generaltechnicaldescription

3.2 Description of This chapter is intended to help you understand the sequence of
the functions functions for the machine so that you can restrict the field of the ma

chine’s applications to suitable areas and avoid errors in operation.

3.2.1 Boom The boom arms are of box construction. They are actuated
hydraulically.
Arm hinges with excellent angular range, in combination with the
powerful slewing gear with its wide slewing range, provide highly
flexible movement.

3.2.2 Delivery line 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 hinges
and pipe connectors.
The pipe elbow hinge at the end of the boom acts as a brake on the
falling concrete and reduces the wear on the end hose. Just like the
delivery line, the end hose is suitable for an operating pressure of
upto 85 bar when new, thanks to its steel cord reinforced fabric.

3.2.3 Hydraulic control All boom movements are effected hydraulically. All boom cylinders
have two integral check valves to provide protection against over

loading or rupture of the hydraulic lines.
The hydraulic fluid supply is sufficient to operate a number of cylin

ders simultaneously. The hydraulic control system can be operated
from the boom pedestal or using a portable remote control unit. The
control slide valves are activated electrohydraulically.

The hydraulic fluid reservoir is integrated in the boom pedestal.

3.2.4 Climbing system The tubular column climbs hydraulically by means of a cylinder. The
system is operated through its own remote control unit. The hydraulic
fluid is supplied through its own hydraulic pump and two hoses with
quick−release connectors.

MX02_350_0709EN 33
 Generaltechnicaldescription

3.3 Technical data

Components Length Width Height Weight
Arm assembly 8970 kg
MX 36−4 Multi 10.8 m 2.6 m 2.74 m (6210 kg
with boom pedestal + 2760 kg)
Boom pedestal with
2.1 m 2.6 m 1.4 m 2760 kg
adapter and delivery line
Working platform
2.4 m 1.8 m 1.3 m 360 kg
(assembly)
0.85 m 0.85 m 3m 1630 kg
Tubular column with 0.85 m 0.85 m 6m 2790 kg
delivery line 0.85 m 0.85 m 9m 3940 kg
0.85 m 0.85 m 10.5 m 4540 kg
Climbing column 0.85 m 0.85 m 1.5 m 1250 kg
Climbing system 10.0 m 0.5 m 0.5 m 830 kg
Set of bottom plates
− − − 4 x 42 kg
(4 pieces)
Set of corner brackets,
− − − 12 x 35 kg
(3x 4 pieces)
Ladder element 2.9 m 0.55 m 0.3 m 28 kg
Back protection 2.9 m 0.8 m 0.8 m 32 kg
Cruciform base, compact 2.9 m 0.8 m 0.8 m 713 kg
Cruciform base for tie rods 2.27 m 2.27 m 1.14 m 1210 kg
Set of tie rods − − − 580 kg
Ballastable cruciform
5.92 m 5.92 m 0.5 m 5780 kg
base
Foundation anchor 1.1 m 1.1 m 1.85 m 1020 kg
Arm assembly
1.7 m 1.9 m 1.0 m 375 kg
transportframe, 2−part
Boom pedestal
0.4 m 1.0 m 0.5 m 250 kg
transportframe

34 MX02_376_0810EN
 Generaltechnicaldescription

3.3.1 Hydraulic pack The hydraulic pack is driven by an electric motor rated as follows:
Voltage Frequency Power
400 V 50 Hz 15 kW

3.3.2 Electrical equipment Putzmeister placing booms are equipped as standard with electric
motors complying with ISO class B. The permissible voltage toler

ance for mains voltage fluctuations for these electric motors is "5%.

Motor and control elements are protected as standard at least to

degree of protection IP54. IP54 means:
− Complete protection against contact with live components or inter

nal moving parts. Protection against damaging dust accumulation.
− Water spraying on the equipment from random directions shall not
have a damaging effect.

3.3.3 Supply cable You will require the following supply cable for the electrical connec

tion; this cable is not included in the products supplied with the
boom:
− 5x6 mm@ rubber−insulated flexible cable
− CEE 5pin standard connector, 32amperes.

3.3.4 Noise emission Noise emission measurement (sound pressure level) for stationary
measurement booms gave a result of 83 dB(A).

Measurement was carried out in accordance with DIN45635Part1

on the working platform at 1m from the boom pedestal and 1.60m
above the working platform deck.

3.3.5 Place of work The machine operator’s place of work is with the cable remote con

trol or the radio remote control. In emergency operation, the place of
work is on the working platform. Generally, the working platform is
only provided for assembly and maintenance work.

MX02_269_0611EN 35
 Generaltechnicaldescription

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

1 Verteilermast
2 MXR 36–4 Multi

3
180200562
4 6

7 8

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 truckmounted concrete pumps, the weight specified
bythe vehicle manufacture applies as per 76/114/EEC:
"Official permitted total weight specified by manufacturer".

36 BP22_830_1005EN
 Generaltechnicaldescription

3.3.7 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

BP22_598_1004EN 1

BP22_598_1004EN 37
 Generaltechnicaldescription

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)
Model (maximum permitted outside diameter
12
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)
Model (maximum permitted outside diameter
19
and wall thickness of the delivery line)
20 V1−V10: Pump−riser pipe adapter pipe lengths

38 BP22_598_1004EN
 Generaltechnicaldescription

3.3.8 Reaches The MX 36−4 Multi has the reaches listed below.

180°

99°

3°
1

245°

233°

MX02_379_0810EN

1 Horizontal reach 35.10m

2 Vertical reach 35.10m
3 Depth of reach with 4m end hose 28.60m
4 Slewing circle 365_

MX02_379_0810EN 39
 Generaltechnicaldescription

3.3.9 Transport frame The transport frames are used to stow the arm assembly when it is
not in use.

2 3

MX02_378_0810EN 1

No. 0 Designation
1 Boom pedestal transport frame
2 Arm assembly transport frame
3 Arm assembly transport trestle

310 MX02_378_0810EN
 Generaltechnicaldescription

3.3.10 Slewing circle The boom has a slewing circle of 365°.

Note
Since the boom is rotated by slewing cylinders and racks, it has a
stop in both directions of rotation, i.e. when the slewing cylinders are
fully extended in one direction or the other. The slewing circle from
stop to stop is 365°.
The boom is at the stop when it is on the side of the hydraulic power
pack.

Slewing circle stop

365°

2
MX02_013_0810EN 2

Slewing circle with stops

No. 0 Designation
1 Hydraulic pack
2 Construction site

You will be hindered in your work if the stops are located over the
construction site, as you will continually be having to slew the
placing boom around to the rear in order to be able to cover the
fullrange.

MX02_013_0810EN 311
 Generaltechnicaldescription

Note
The placing boom will be just in front of one of the two stops when
the arm assembly is above the hydraulic power pack.

In order to be able to cover the area to be concreted, the construc

tion site must be located on the side facing the delivery line.

The tubular column must therefore be fitted in such a way that the
ladder is located on the side facing the construction site.

312 MX02_013_0810EN
 Generaltechnicaldescription

3.4 Symbols for the This section gives you a summary of the various control devices on
control system the machine and the symbols used for control actions.

The functions of the machine are assigned to the following control

devices:
− Control cabinet
− Control block for boom functions
− Cable remote control
− Radio remote control (optional)

3.4.1 General symbols

1 2 3 4

0 I

5 6 7

20201301

No. 0 Designation
1 Horn
2 EMERGENCY STOP
3 Concrete pump On − Off
4 Climbing function
5 Motor Off
6 Motor On
7 Climbing cylinders emergency manual operation

MX02_007_0905EN 313
 Generaltechnicaldescription

3.4.2 Boom

1 2 3 4

5 6 7 8

9 10 11 20201500

No 0 Designation
1 Slew boom to the right
2 Slew boom to the left
3 Arm 1 up
4 Arm 1 down
5 Arm 2 up
6 Arm 2 down
7 Arm 3 up
8 Arm 3 down
9 Arm 4 up
10 Arm 4 down
11 Boom function

314 MX02_014_9709EN
 Generaltechnicaldescription

3.5 Electrical control The electrical control devices and operating elements on this machine
devices are described on the following pages. The overview 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
− Chain hoist control cabinet
− Squeeze valve control panel
− Cable remote control
− Radio remote control
− Chain hoist remote control unit
− Climbing cylinders remote control unit

Note
Further control devices and components are described in the

Hydraulic control devices" (from page 325) and
Other compo
nents" (from page 330) sections.

MX02_372_0810EN 315
 Generaltechnicaldescription

3.5.1 Control cabinet The control cabinet is shown below. Depending on the configuration,
some of the control and operating elements shown may not be present.
The hole will be filled with a blanking plug if a control or operating
element is omitted.

1 2 3 4 5 6 7 8 9

10

11

16 12

15 14 13
MX02_405_1008EN 1

Operating/ Belongs
No. 0 Meaning/Function
control element with no.:
1 Keyswitch Local control − 0 − Remote control
2 Toggle switch Motor On − Off
3 White indicator lamp Ready for operation
4 Toggle switch Horn + deactivate EMERGENCY STOP
5 Red indicator lamp Motor overheating
6 Red indicator lamp EMERGENCY STOP activated
7 Green indicator lamp Interim lubrication On 15
8 Operating hours meter Operating hours display
9 Key for control cabinet
10 Female connector Boom remote control connection
11 Female connector Climbing cylinder remote control
connection
12 Female connector Control cabinet pump connection
13 Toggle switch Interim lubrication 9
14 Momentary−contact switch EMERGENCY STOP
15 Connector Power supply
16 Main switch Disconnects the control cabinet

316 MX02_405_1008EN
 Generaltechnicaldescription

Special features of the control cabinet

Switchover from remote The EMERGENCY STOP circuit is activated automatically when you
to local control switch over from remote to local control. You must operate the horn
to deactivate the EMERGENCY STOP circuit.

MX02_405_1008EN 317
 Generaltechnicaldescription

3.5.2 Squeeze valve You can preselect the function of the squeeze valve on the squeeze
control panel valve control panel.

BP02_551_9802EN 1

Operating/
No 0 Meaning/Function
control element
1 Toggle switch Squeeze valve On − Off

Special features of the squeeze valve control panel

Squeeze valve A pneumatically operated squeeze valve is mounted between the

delivery line bend on the last boom arm and the end hose. This
squeeze valve closes off the delivery line when the pump stops. The
delivery line will be shut off as soon as you switch the pump off at the
remote control if the squeeze valve is activated at the "Squeeze
valve On−Off" toggle switch. The squeeze valve opens as soon as
you re−start the pump at the remote control.
See also: Squeeze valve (page 337)

318 BP02_551_9802EN
 Generaltechnicaldescription

3.5.3 Cable remote control The standard cable remote control for this machine is illustrated
below.

9
2 ÁÁ
ÁÁ
10
1 3
8

7
5

6 MX02_380_0905EN 1

Operating/ Belongs
No. 0 Meaning/Function
control element with no.:
1 Joystick Boom control
2 Rotary controller (optional) Sets the boom speed if no.6 is switched 6
to the Slow" switch position
3 Toggle switch Pump On − Off
4 Toggle switch Horn + deactivate EMERGENCY STOP
5 Rotary controller Increase − Reduce output
6 Toggle switch (optional) Preselect boom speed: 2
fast = 100% / slow = 0−100%
7 Toggle switch Motor On − Off
8 Locally latched toggle switch Boom functions − 0 − climbing function
9 Red indicator lamp Fault (e.g. EMERGENCY STOP operated)
10 Momentary−contact switch EMERGENCY STOP

MX02_380_0905EN 319
 Generaltechnicaldescription

Special features of the cable remote control

Restarting the pump The red Fault" indicator lamp lights up and the green Pump run

after EMERGENCY ning" indicator lamp flashes when the EMERGENCY STOP button is
STOP pressed. You may only start the pump up again as described below:
− Unlock the EMERGENCY STOP button by turning it,
− press the Horn + deactivate EMERGENCY STOP" toggle switch
(red indicator lamp goes out),
− switch the pump off and then back on again at the Pump On−Off"
toggle switch (pump runs and the green indicator lamp lights up).

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

Squeeze valve When the Squeeze valve" function is activated on the control panel:
− the squeeze valve closes as soon as the pump is switched off
using the Pump On/Off" toggle switch.
− the squeeze valve opens as soon as the pump is switched on
using the Pump On/Off" toggle switch.

320 MX02_380_0905EN
 Generaltechnicaldescription

3.5.4 Chain hoist

remote control unit

MX02_355_0905EN 1

No. 0 Operating/control element Meaning/Function

1 Momentary−contact switch EMERGENCY STOP
2 Momentary−contact switch Hoisting
3 Momentary−contact switch Lowering

MX02_355_0905EN 321
 Generaltechnicaldescription

3.5.5 Climbing cylinders

remote control unit

MX02_294_0509EN 1

Operating/
No. 0 Meaning/Function
control element
1 Key−operated switch Ready for operation On − Off
2 Toggle switch Climbing cylinders,
extending −retracting

322 MX02_294_0509EN
 Generaltechnicaldescription

3.5.6 EMERGENCY STOP The EMERGENCY STOP button is located on the cable remote
button control.

MX02_061_0905EN 1

EMERGENCY STOP button

Note
You must press the EMERGENCY STOP button to trigger an EMERG
ENCY STOP of the machine.

To release the EMERGENCY STOP condition again, you must unlock

the EMERGENCY STOP button that has been pressed by turning it
and sound the horn.

You must switch the hydraulic pump back on to bring the boom back
into service.

MX02_061_0905EN 323
 Generaltechnicaldescription

The following actions are triggered in the boom system when you
press one of the EMERGENCY STOP buttons:

System Action

Boom − the boom control block is disconnected.

− the supply voltage to the cable remote control
system, with the exception of that for the horn,
is switched off, the Concrete pump On" indica

tor lamp on the cable remote control unit
flashes
− the EMERGENCY STOP activated" indicator
lamp on the control cabinet lights up
− the gate valve at the boom tip can no longer be
operated
− The boom pump transports hydraulic fluid in
depressurized circulation (maximum15bar)
through the boom control unit inlet module to
the tank. Emergency operation of the boom
functions is ensured by simultaneous manual
operation of the operating mode selector valve
and the corresponding boom arm valve.

Danger
The machine is only switched off electrically when the EMERGENCY
STOP button is pressed. Although this causes all the electrically
actuated hydraulic valves to be switched off, an uncontrolled sinking
of the boom caused by leakages in the hydraulic system, for instance,
cannot be prevented in this way.

In no event should you first press the EMERGENCY STOP button if

the boom starts uncontrolled movements. Should you do this you will
have no ability to counteract the movement.

324 MX02_061_0905EN
 Generaltechnicaldescription

3.6 Hydraulic control The hydraulic 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 hydraulic
control devices are described in one of the preceding sections.

The hydraulic control devices may include the following components,

depending on the equipment on your machine.
− Control block
− Climbing system

Note
Further control devices and components are described in the

Electrical control devices" (from page 315) and
Other
components" (from page 330) sections.

MX02_093_9706EN 325
 Generaltechnicaldescription

3.6.1 Boom functions The control block can be operated manually and thus provides secur

control block ity of operation if a malfunction occurs in the remote control system.
The control block for normal operation is fitted with a guard to ensure
that the operating levers are not operated accidentally. Youcan use
the emergency manual operation system to control the climbing cylin

ders in the event of failure of the climbing system remote control.

1 2 3 4 5 6

7 8

22002101

No 0 Designation
1 Arm 4 up − down
2 Arm 3 up − down
3 Arm 2 up − down
4 Arm 1 up − down
5 Slew boom to the right − to the left
6 Operating mode selector valve:
boom function − climbing function
7 Pressure gauge 0 − 400 bar
8 Emergency manual operation for climbing function

10200500

Emergency manual operation button

326 MX02_015_9709EN
 Generaltechnicaldescription

3.6.2 Climbing system Once the placing site has reached a height at which the freestanding
placing boom can no longer easily be used, it is necessary to shift
the tubular column upwards. This process of shifting upwards is
known as climbing.

MX02_353_0808EN 1

Climbing system

No. 0 Designation
1 Chain hoist
2 Climbing rail
3 Tubular column
4 Upper climbing carriage
5 Climbing cylinder
6 Lower climbing carriage

MX02_353_0808EN 327
 Generaltechnicaldescription

Climbing procedure The tubular column climbs hydraulically by means of a climbing

cylinder.
The climbing cylinder is located on the floor and uses the upper
climbing carriage to push upwards the climbing rail which is
attached to the tubular column.

1. 2. 3. 4. 5.

MX02_353_0808EN 2

No. 0 Designation
1 Climbing rail
2 Upper climbing carriage
3 Upper climbing carriage detent pawl
4 Climbing cylinder
5 Lower climbing carriage
6 Lower climbing carriage detent pawl

328 MX02_353_0808EN
 Generaltechnicaldescription

A climbing procedure consists of several climbing operations.

Aclimbing operation proceeds as follows:
− As the climbing cylinder lifts, the tubular column is pushed
upwards (1.).
− Before the end of the lift, the detent pawl of the lower climbing
carriage engages in the climbing rail and holds the tubular column
in position (2.).
− In the next operation, the climbing cylinder is retracted (3.).
− Before the end of the cylinder’s return travel, the detent pawl of the
upper climbing carriage engages in the climbing rail (4).
− The new starting position (5.) has now been reached. The climbing
operation is complete and can now be repeated.

MX02_353_0808EN 329
 Generaltechnicaldescription

3.7 Other components The other components of this machine are described on the follow

ing pages. The overview at the start of this chapter will show you
where the various components are located on the machine.

The following components may be described here, depending on

the equipment on your machine.
− Cruciform base
− Climbing system
− Corner brackets
− Bottom plates
− Climbing column
− Chain hoist
− End hose
− Squeeze valve

Note
Further control devices and components are described in the

Hydraulic control devices" (from page 325) and
Electrical con
trol devices" (from page 315) sections.

330 MX02_354_0810EN
 Generaltechnicaldescription

3.7.1 Cruciform base The cruciform base supports the tubular column of the freestanding
placing boom.

MX02_367_0807EN 1

Cruciform base

Note
The foundation on which the cruciform base is set up must be
prepared in accordance with the requirements.

MX02_367_0807EN 331
 Generaltechnicaldescription

Template of ballastable
cruciform base

MX02_367_0807EN 2

Ballastable cruciform base

332 MX02_367_0807EN
 Generaltechnicaldescription

Cruciform base with ballast

MX02_367_0807EN 3

Cruciform base with ballast beam

Note
The weight of the concrete ballast depends on the size of the tubular
column and the placing boom.
Request the relevant information about the required dimensions of
the concrete ballast from Putzmeister.

MX02_367_0807EN 333
 Generaltechnicaldescription

3.7.2 Corner bracket The corner brackets support the tubular column in the holes in the
floor when the tubular column is no longer standing on the cruciform
base.

Note
The corner brackets are fitted in the corners of the holes in the storey
floor. The floor must be sufficiently well concreted to support the
forces transmitted from the placing boom.

Hole in floor
1

2
MX02_373_0808EN 1

Dimensions of the hole in the floor

1 1000 mm
2 1000 mm

Danger
Damage may be caused to the placing boom or to the floor when the
column climbs if the holes in the floor do not precisely match the
dimensions specified.

The holes in the floor must lie precisely one over the other. The placing
boom may be skewed if they are not precisely one over the other.
This leads to loading in the slewing gear and can also be detrimental
to stability.

334 MX02_373_0808EN
 Generaltechnicaldescription

MX02_373_0808EN 2

Corner brackets fitted to the hole in the floor

No. 0 Designation
1 Wedge
2 Anchorage

MX02_373_0808EN 335
 Generaltechnicaldescription

3.7.3 Bottom plate The tubular column stands on bottom plates when it is clamped
using the corner brackets in the holes in the floor.

MX02_374_0808EN 1

No. 0 Designation
1 Corner bracket 4x
2 Bottom plate 4x

336 MX02_374_0808EN
 Generaltechnicaldescription

3.7.4 Squeeze valve The squeeze valve is pulled onto the end hose and is used to inter

rupt the flow of concrete so that no concrete leaks out of the delivery
line during brief breaks in pumping. This is particularly useful in
applications such as
− concreting of foundations or
− underwater concrete placement or
− in jobs where the concrete must be precisely dosed".

Danger
The squeeze valve is pulled onto the upper end of the end hose and
must always be secured against falling using the two safety cables.

The safety cables must be affixed to the hose clamp. Fastening the
safety cables to the coupling is prohibited as the squeeze valve
could fall when the coupling is opened.

Check the safety cables for damage every day. A damaged safety
cable must be replaced by a new one immediately.

MX02_299_0801EN 337
 Generaltechnicaldescription

4 5 7

+
10
1 2 3
MX02_299_0801EN 1

No. 0 Designation
1 Compressed air supply shut−off valve
2 Squeeze valve control toggle switch
3 Toggle switch for pump On/Off at the remote control
4 Squeeze valve (open)
5 Squeeze valve (closed)
6 Elbow on the last arm
7 Safety cable
8 End hose
9 Squeeze valve

338 MX02_299_0801EN
 Generaltechnicaldescription

Special features of the squeeze valve

The squeeze valve is supplied with compressed air from the con

struction site. A shut−off valve, which has to be opened in order to
activate the squeeze valve, is installed in the compressed air supply
line.
You can activate the squeeze valve at the control cabinet or at a
separate control panel.
The squeeze valve is activated in accordance with the operating
state as follows:
− The squeeze valve opens when you switch on the pump.
− The squeeze valve closes when you switch off the pump.
− The squeeze valve opens if you set the pump to reverse pumping
to allow cleaning.

MX02_299_0801EN 339
 Generaltechnicaldescription

3.7.5 End hose The machine is fitted with an end hose permitted for the required
stability. This depends on a number of factors:
− End hose length
− End hose diameter
− Self−weight of the end hose

The machine card for this machine will tell you which end hose is
approved for the machine. The maximum permissible end hose
length is also indicated on the boom rating plate.

Danger
It is forbidden, under normal conditions of use, to extend the end
hose or to fit an end hose longer than that specified on the rating
plate. It is further forbidden to use an end hose with a greater
diameter or higher weight. The machine can tip over if you use a
prohibited end hose.

You may only use a different end hose (e.g. a longer end hose to fill
deep formwork) if this is expressly described in these Operating
Instructions (see
Use of the xm end hose" section).

340 BP02_371_0607EN
 Generaltechnicaldescription

End hose with End hoses may not be fitted with any extension coupling, outlet
flow restrictor shoes or other dangerous outlet fitting. You can use the modified
Putzmeister end hose with flow restrictor if you wish nevertheless
toachieve a uniform flow of the concrete for filling hollow blocks.

Products supplied
ÂÂ
ÂÂ
ÂÂÂ
ÂÂ
ÂÂÂ
ÂÂ
ÂÂÂ
ÂÂ
ÂÂÂ
ÂÂ
ÂÂÂ
1

ÂÂ
ÂÂÂ
2
ÂÂ
ÂÂÂ
ÂÂ
ÂÂÂ
3

32500601

No. 0 Designation
1 Rubber protective sleeve
2 Modified end hose
3 Push−in spout
4 Flow restrictor

Danger
The end hose with flow restrictor may only be used for filling hollow
blocks. The rubber protective sleeve must always be pulled fully
down over the push−in spout, whether or not you are using the flow
restrictor. The end hose may no longer be used if the protective
sleeve is damaged or missing entirely.

BP02_371_0607EN 341
 Generaltechnicaldescription

Retaining rope The end hose is permanently exposed to high loads and severe
on the end hose wear. It is, therefore, possible that a heavily worn end hose may tear
at the push−on connection. The retaining rope prevents the end hose
from falling.

2 ÂÂÂ
ÂÂÂ
3

ÂÂÂ
ÂÂÂ
ÂÂÂ
4

BP02_371_0607EN 2

No. 0 Designation
1 Snap hook
2 Retaining rope
3 Push−on connection
4 Hose clamp

Danger
The retaining rope prevents the end hose falling if it tears away or if
the coupling is opened. The end hose must therefore always be
secured by a retaining rope.

The retaining rope must be passed around one of the clamping bolts
on the hose clamp and secured to the boom by the snap hook.
Fastening the retaining rope to the coupling is prohibited as the
endhose would fall when the coupling was opened.

Check the retaining rope for damage every day. A damaged retaining
rope must be replaced by a new retaining rope immediately.

342 BP02_371_0607EN
 Generaltechnicaldescription

Dual–section To connect a continuation delivery line easily, you can use the dual−
end hose with section end hose with protective bell.
protective bell

4
5
6

10

11

BP02_371_0607EN 3

No. 0 Designation
1 Delivery hose
2 Protective bell
3 Push−on connection
4 Hose clamp
5 Securing bolt with nut
6 Seal ring
7 Clamp coupling
8 Retaining rope with two snap hooks
9 Hose clamp
10 Push−on connection
11 End hose

BP02_371_0607EN 343
 Generaltechnicaldescription

Danger
To safeguard against the dual−section end hose falling, the delivery
hose must be secured to the boom tip with a retaining rope and
theend hose must be secured to the delivery hose with another
retaining rope. Check the retaining ropes for damage every day.
Adamaged retaining rope must be replaced by a new retaining
ropeimmediately.

The connection point between the delivery hose and end hose is
located overhead. Nevertheless, to minimise the risk of injury to the
hoseman, the protective bell must always be pulled down over the
connection point.

The overall length of the dual−section end hose must not exceed the
permissible end hose length, as this would otherwise cause the
machine to tip over.

The dual−section end hose may only be used in the fully−assembled

condition. The lower end may not be fitted with any extension coupling,
outlet shoes or other dangerous outlet fitting. There is otherwise a
risk of injury if the end hose swings out.

344 BP02_371_0607EN
 Generaltechnicaldescription

3.7.6 Torque wrench set It is important that the bolts are tightened to the torques specified
when the stationary boom is assembled.

Note
The bolts may only be tightened correctly and precisely if a torque
wrench set is used.

You can obtain torque wrench sets from Putzmeister for the assembly
of stationary booms.

42900100

1 Torque wrench
2 Torque wrench socket

Together with the torque wrench, the torque wrench socket makes up
a tool which makes it possible to transfer precise torques.

MX02_055_0105EN 345
 Generaltechnicaldescription

Technical data The table below shows the technical data for the torque wrench set
you can obtain from Putzmeister:

Torque wrench
Model 7003
Part number AN 268365.008
Measuring range Nm 50−200
Drive square 1/2"
Length approximately mm 520
Weight kg 1.2

Torque wrench socket

Part number AN 268362.001
Load Nm 3200
Ratio 1:16
Diameter mm 88
Socket 3/4"
Drive square 1"
Height mm 235
Weight kg 4.7

Socket spanner
Part number AN 268366.007
Reduction 1" /width across flats 50

346 MX02_055_0105EN
 4 Transport, assembly and connection

This chapter contains information relating to transporting the

machine. In addition it describes the work required for the
assembly,connection and disassembly of the machine.
Startingupthe machine is described in the Operation"
chapter.

MX05_006_9502EN
 Transport,assemblyandconnection

4.1 Transport Transport the various assemblies only on their transport frames on
the bed of an adequately sized truck. Observe the following points
inorder to give the boom adequate stability during the journey:
− Secure the end hose.
− Check the securings (1) − (3) on the transport frames.
− Lash the transport frames down to the truck bed using suitable
means.

2
3
1

MX05_303_0810EN 1

Securings on the transport frame

When working at height, use the climbing aids and working plat

forms provided for reasons of safety or wear a safety harness.
Therelevant national regulations must be complied with.

MX05_303_0810EN 41
 Transport,assemblyandconnection

4.1.1 Lifting points

When working at height, use the climbing aids and working plat

forms provided for reasons of safety or wear a safety harness.
Therelevant national regulations must be complied with.

Note
Ensure that the load is distributed evenly between the lifting eyes.
The component can be guided and positioned more easily once it
has been attached.

Cruciform base,
climbing column,
tubular column
element

MX05_312_0810EN 1

Lifting points on the cruciform base and climbing column, and

on a tubular column element

Use the two inner lifting eyes (1) for transporting the cruciform base,
climbing column or a tubular column element.
You can preassemble the whole tubular column in a horizontal posi

tion. It is possible to attach a tubular column with an overall length of
up to 19.5m.

42 MX05_312_0810EN
 Transport,assemblyandconnection

You can lift the boom pedestal either with or without the tubular
column fitted.

Boom pedestal with-

out tubular column
fitted 2 2

MX05_312_0810EN 2

Lifting points at the top of the boom pedestal

No. 0 Designation Comments

1 Boom pedestal with pinion adapter 2760kg
2 Lifting points at the top of the boom
pedestal

Use the two lifting points (2) attached to the top of the boom
pedestal for transporting the boom pedestal without a tubular
column fitted.
The lifting eyes are each designed to carry a weight of 3.2t
withquadruple safety.

MX05_312_0810EN 43
 Transport,assemblyandconnection

Boom pedestal with

tubular column fitted
3
1

Î 3

MX05_312_0810EN 3

Lifting points at the side of the boom pedestal

No. 0 Designation
1 Boom pedestal with tubular column fitted
2 Pinion adapter
3 Lifting points at the side of the boom pedestal

Use the two lifting points (3) attached to the side of the boom
pedestal for transporting the boom pedestal with a tubular column
fitted.
The lifting eyes are each designed to carry a weight of 10t with
quadruple safety.

Danger
It is prohibited to lift the boom pedestal when a tubular column is
fitted by using the lifting points attached to the top of the boom
pedestal.
There is a risk that the lifting point will be overloaded and that, after
lifting, the component may fall.

44 MX05_312_0810EN
 Transport,assemblyandconnection

Before attaching the boom pedestal, you must turn the pinion
adapter to a position where it cannot come into contact with the
transport cable during transportation. You can turn the pinion
adapter using the manual control, or the remote control after
connecting the electric motor and the remote control system,
asdescribed on page 473.

MX05_312_0810EN 45
 Transport,assemblyandconnection

Arm assembly You can use the arm assembly either as a mobile boom or as a
stationary boom.
You can transport the arm assembly either with or without the boom
pedestal fitted. The lifting points and the weights of the individual
assemblies are listed below.

3 4
2
B

5 6

MX05_304_0811EN 1

No. 0 Designation Comments

1 Transport chain container
2 Shortening claw
3 Arm assembly lifting tackle (1 x cable, 2 x transport chain)
4 Lifting eye
5 Arm assembly without boom pedestal 6210kg
6 Arm assembly with boom pedestal 8970kg

46 MX05_304_0811EN
 Transport,assemblyandconnection

Observe the following points when transporting the arm assembly

using a crane:
− Only use the appropriate lifting tackle (3).
− When fitting the lifting eye (4), make sure that the markings A
andB are aligned as illustrated above.
− Balance the centre of gravity with the shortening claw (2) on the
transport chain so that the arm assembly hangs horizontally.
− Unhook the lifting tackle from the crane once transportation is
complete. Secure the cable to the arm assembly and stow the
transport chain and the shackles in the container (1).

The lifting points for crane hooks on the placing boom have been
designed with a safety factor of 1.8.

MX05_304_0811EN 47
 Transport,assemblyandconnection

4.2 Assembly With your order confirmation, you will have received the following
documentation which you will require to have the site for the placing
boom prepared correctly:
− Quotation drawing
− Assembly plan
− Foundation plan

When working at height, use the climbing aids and working plat

forms provided for reasons of safety or wear a safety harness.
Therelevant national regulations must be complied with.

Danger
Guide components being hoisted with guy ropes. This prevents the
components swinging and injuring persons in the vicinity or causing
damage. In addition, the hoisted components can be positioned
more easily.

48 MX05_281_0810EN
 Transport,assemblyandconnection

4.2.1 Limit parameters

Caution
The maximum overall length of the tubular columns specified here
must not be exceeded, as there is otherwise a risk of overloading
thestationary boom.
If you wish to use the placing boom in other conditions, you must
request the relevant documents from Putzmeister.

Freestanding stationary boom

MX05_300_0808EN 1

No. Length of the tubular column ... Height of job 0 – 20.5 m

A for freestanding stationary boom, max. 20.5 m
Boom rest position vertical

MX05_300_0808EN 49
 Transport,assemblyandconnection

Stationary boom, clamped in position

D
MX05_300_0808EN 2

No. Length of the tubular column ... Height of job > 20.5 m
A for clamped stationary boom, max. 19.5 m
B above the uppermost fixing point, max. 15.5 m
C between two fixing points, min. 3m
D below the last fixing point 1m
Boom rest position and climbing position vertical

410 MX05_300_0808EN
 Transport,assemblyandconnection

4.2.2 Fitting the cruciform The cruciform base can be fitted on a foundation anchor or a ballast

base on the founda- able cruciform base.
tion anchor

Preparing the foundation anchor

90mm

0.5°
10m

MX05_286_0810EN 1

Deviation for 10m tubular column

Danger
The cruciform base must not deviate from the horizontal by more
than 0.5° so that the tubular column subsequently deviates from the
vertical by no more than 0.5°.

Note
A 0.5° deviation of the tubular column from a vertical position results
in a deviation of 9 mm per 1 m of the tubular column. Thus the top
end of a 10 m tubular column will deviate from the centre point by
90mm.

MX05_286_0810EN 411
 Transport,assemblyandconnection

Structure of foundation anchor

MX05_286_0810EN 2

No. 0 Designation
1 Prepared foundation
2 Nut 80x
3 Washer 80x
4 Tie rod 20x

412 MX05_286_0810EN
 Transport,assemblyandconnection

Setting up the foundation anchor on the horizontal

MX05_286_0810EN 3

No. 0 Designation
1 Foundation anchor
2 Nut 20x

" Place the spirit level on the foundation anchor and align the
anchor horizontally, using the nuts underneath it.

" Before concreting the foundation, tighten the nuts to a torque

of100 Nm.

" During concreting, protect the threads of the tie rods.

MX05_286_0810EN 413
 Transport,assemblyandconnection

Fitting the cruciform base

MX05_286_0810EN 4

Foundation for cruciform base

" After concreting, undo and remove the nuts and washers from
the tie rods.

414 MX05_286_0810EN
 Transport,assemblyandconnection

Note
Make sure that the cruciform base is correctly aligned. The arrows in
the illustration show the direction of the construction site.

MX05_286_0810EN 5

Orientation of cruciform base

" Place the cruciform base onto the foundation anchor.

MX05_286_0810EN 415
 Transport,assemblyandconnection

MX05_286_0810EN 6

Setting up the cruciform base on the horizontal

" Place the spirit level on the cruciform base and align it so that
itis horizontal.
å To do this, you may have to lay packing shims under the
cruciform base.

416 MX05_286_0810EN
 Transport,assemblyandconnection

Danger
Only use the nuts specified by Putzmeister. Putzmeister does not
accept liability for damage arising from the use of other nuts.

MX05_286_0810EN 7

Assembling the cruciform base

No. 0 Designation
1 Torque wrench set
2 Nut 20x
3 Washer 20x

" Using the torque wrench set, tighten the fastening nuts to a
torque of 2200Nm.

Note
If you do not use the torque wrench set to assemble the foundation
anchor, you will have to request appropriate documentation from
Putzmeister for the required torque setting.

MX05_286_0810EN 417
 Transport,assemblyandconnection

4.2.3 Fitting the cruciform The cruciform base can be fitted on a foundation anchor or a ballast

base onto the ballast- able cruciform base.
able cruciform base

Note
The weight of the concrete ballast depends on the size of the tubular
column and the placing boom.
Request the relevant information about the required dimensions of
the concrete ballast from Putzmeister.

Arrange for the ballast for the ballastable cruciform base to be

manufactured according to specification.

418 MX05_299_0810EN
 Transport,assemblyandconnection

90mm

0.5°

10m

MX05_299_0810EN 1

Deviation for 10m tubular column

Danger
The cruciform base must not deviate from the horizontal by more
than 0.5° so that the tubular column subsequently deviates from the
vertical by no more than 0.5°.

Note
A 0.5° deviation of the tubular column from a vertical position results
in a deviation of 9 mm per 1 m of the tubular column. Thus the top
end of a 10 m tubular column will deviate from the centre point by
90mm.

Danger
Only use the nuts specified by Putzmeister. Putzmeister does not
accept liability for damage arising from the use of other nuts.

MX05_299_0810EN 419
 Transport,assemblyandconnection

Assembling the ballastable cruciform base

1 2

MX05_299_0810EN 2

" Fit the two smaller girders (1) of the cruciform base to the
larger girder (2).

" Using the torque wrench set (4), tighten the 17 fastening
nuts(3) on each girder to a torque of 1650 Nm.

Note
If you do not use the torque wrench set to assemble the foundation
anchor, you will have to request appropriate documentation from
Putzmeister for the required torque setting.

420 MX05_299_0810EN
 Transport,assemblyandconnection

MX05_299_0810EN 3

Setting up the cruciform base on the horizontal

" Place the spirit level on the cruciform base and align it so that
itis horizontal.
å To do this, you may have to lay packing shims under the
cruciform base.

MX05_299_0810EN 421
 Transport,assemblyandconnection

Fitting the cruciform base

Note
Make sure that the cruciform base is correctly aligned. The arrows in
the illustration show the direction of the construction site.

MX05_299_0810EN 4

Orientation of cruciform base

" Place the cruciform base on the ballastable cruciform base.

422 MX05_299_0810EN
 Transport,assemblyandconnection

Danger
Only use the nuts specified by Putzmeister. Putzmeister does not
accept liability for damage arising from the use of other nuts.

MX05_299_0810EN 5

Fitting the cruciform base onto the ballastable cruciform base

No. 0 Designation
1 Bolt 20x
2 Washer 40x
3 Nut 20x

" Insert the 20 fastening bolts into the holes and tighten the
fastening nuts with a torque of 1650 m.

MX05_299_0810EN 423
 Transport,assemblyandconnection

Placing the ballast

MX05_299_0810EN 6

No. 0 Designation
1 Ballast

" Place the ballast on the ballastable cruciform base.

424 MX05_299_0810EN
 Transport,assemblyandconnection

4.2.4 Assembling the The maximum overall length of the assembled tubular column is
tubular column given in the limit parameters on page 49.

Pre–assembly of Pre−assemble the elements of the tubular column before you erect
the tubular column the tubular column.
elements Depending on the tubular column elements and the particular
deployment of the stationary boom, pre−assembly can consist of
thefollowing steps:
− Connecting the tubular column elements
− Fitting the climbing system
− Fitting the ladder elements
− Mounting the platform

If you wish to use a freestanding stationary boom in a climbing

operation at a later date, you must make sure that the tubular column
which accommodates the climbing system closes at the bottom with
a climbing column and has an overall length of 10.50 m.

MX05_288_0807EN 425
 Transport,assemblyandconnection

Assembly example of a freestanding stationary boom for use in a climbing operation

at a later date
Instead of the intermediate platform, you can also use simple ladder
elements.

7
1
4 8
1
2

1
4

9
6

10

MX05_288_0807EN 1

Assembly example for a freestanding stationary boom

426 MX05_288_0807EN
 Transport,assemblyandconnection

No. 1 Description Height

1 Working platform ladder 1.3 m
2 Working platform 1.4 m
3 Ladder with back protection for the transition to the platform 2.0 m
4 Ladder with back protection 2.9 m
5 Intermediate platform ladder with back protection 3.7 m
6 Climbing column ladder 1.6 m
7 Climbing system 10.0 m
8 Tubular column element 9.0 m
9 Climbing column 1.5 m
10 Ballastable cruciform base 1.0 m

MX05_288_0807EN 427
 Transport,assemblyandconnection

4.2.5 Connecting the tubular column elements

Note
The following assembly operations are presented in order to show an
example of installing a tubular column element vertically on the cruci
form base. The assembly operations can also be used analogously
for installing individual tubular column elements horizontally.

MX05_289_0807EN 1

Removing the clamp coupling

" Remove the clamp coupling from the end of the delivery pipe
and slide the seal back onto the delivery pipe.

Note
Grease all couplings and seals well internally before assembly.
Usea lithium soap base multipurpose grease labelled K2K.

428 MX05_289_0807EN
 Transport,assemblyandconnection

MX05_289_0807EN 2

Raising the tubular column element

" Raise the tubular column element.

MX05_289_0807EN 429
 Transport,assemblyandconnection

MX05_289_0807EN 3

Placing the tubular column element on the cruciform base

" Place the tubular column element on the cruciform base.

" Make sure that there is a gap of 4 mm between the ends of the
delivery pipe of the tubular column element and the cruciform
base.

" Raise the tubular column element and slide the seal on the
delivery pipe of the cruciform base onto the weld−on ring.

" Place the tubular column element on the cruciform base and
press the delivery pipe of the tubular column element into the
seal down to the stop.

" Fit the coupling and secure it.

430 MX05_289_0807EN
 Transport,assemblyandconnection

MX05_289_0807EN 4

Connecting the tubular column element

with the cruciform base

" Connect the tubular column element to the cruciform base

using the four pins (1).

1 2
MX05_289_0807EN 5

Securing the pins

" Secure the four pins (1) using the locking plate (2).

MX05_289_0807EN 431
 Transport,assemblyandconnection

Connecting the delivery pipes

MX05_289_0807EN 6

Connecting the delivery pipes

Clearance If the delivery pipes have not been pre−fitted to the tubular column
elements, you must ensure that the individual delivery pipes are cor

rectly spaced when they are fitted. A clearance (1) of 4 mm must be
maintained between the delivery pipes over the whole of the delivery
line, so that the weld−on rings can butt against the couplings without
play. This clearance is achieved either:
− automatically, through the use of a Cseal (triple−lip seal), or
− manually, by adjustment using a feeler gauge or a spacer when
anAseal is used.

Note
Grease all couplings and seals well internally before assembly.
Usea lithium soap base multipurpose grease labelled K2K.

432 MX05_289_0807EN
 Transport,assemblyandconnection

Cseal (triple−lip seal)

4mm

MX05_289_0807EN 7

The spacing is set automatically by the triple−lip seal

" Push the triple−lip seal over the weld−on ring of the fixed
delivery line pipe.

" When fitting the pipe, press it down into the seal as far as
thestop.

" Fit the coupling and secure it.

" Proceed in the same way with the other delivery pipes.

MX05_289_0807EN 433
 Transport,assemblyandconnection

Aseal

2 3
1
MX05_289_0807EN 8

No. 1 Designation
1 Fixed delivery pipe
2 A seal
3 Coupling
4 Spacer (4 mm)
5 Delivery pipe to be fitted

" Push the Aseal(2) over the fixed delivery pipe (1).

" When fitting the delivery pipe (5), lay it onto the nearest
brackets and slide it towards the fixed delivery pipe.

" Locate the spacer (4) between the delivery pipes and fit a
clamp coupling (3).
å This sets the required clearance of 4mm between the
delivery pipes.

" When fitting the delivery pipe, fasten it to the brackets using
pipe brackets.

" Remove the coupling.

" Remove the spacer.

" Push the Aseal over the two weld−on rings.

" Fit the coupling and secure it.

" Proceed in the same way with the other delivery pipes.

434 MX05_289_0807EN
 Transport,assemblyandconnection

Connecting the hydraulic lines

The hydraulic lines on the tubular column connect the hydraulic

power pack on the boom pedestal to the climbing cylinder of the
climbing system.

1 4

2 3 MX05_289_0807EN 9

Connecting the hydraulic lines

" Connect the left−hand connector plug (1) to the left−hand

connector sleeve (2) and the right−hand connector plug (3)
tothe right−hand connector sleeve (4).

MX05_289_0807EN 435
 Transport,assemblyandconnection

4.2.6 Fitting the climbing system

The tubular column which accommodates the climbing system must
close at the bottom with a climbing column and have an overall
length of 10.50 m.
The climbing system is fitted to the tubular column on the side
opposite the delivery pipes.

MX05_290_0807EN 1

Laying down the climbing system

" Position the tubular column in such a way that you can install
the climbing system.

" Lay the climbing system down on the tubular column in such a
way that the brackets (1) on the climbing column fit into the
cut−outs on the climbing rail.

436 MX05_290_0807EN
 Transport,assemblyandconnection

Fitting the
climbing rail

4
6

8 5
7

MX05_290_0807EN 2

No. 1 Description
1 Pin
2 Spring pin
3 Climbing rail
4 Tubular column
5 Spacer sleeve
6 Climbing rail fastening bolt
7 Washers
8 Nut, self−locking

" Secure the climbing rail with the pin (1) and secure the pin with
the spring pin (2).

" Fit the climbing rail (3) to the tubular column (4) using the two
bolts (6), as illustrated above.

MX05_290_0807EN 437
 Transport,assemblyandconnection

4.2.7 Fitting the ladder elements

The ladder elements are fitted on the side where the delivery line is
installed.

Note
The following assembly operations are presented in order to show
anexample of fitting a ladder element to a 3 metre tubular column
element. The procedure for fitting the other ladder elements is
identical.

3 1

MX05_292_0807EN 1

Attaching a ladder element

" Position the tubular column in such a way that you can install
the ladder elements.

" Attach the ladder element (1) to the holders (2) on the tubular
column and secure the ladder element with a spring bolt (3).

" Fit the back protection cage to the ladder element.

438 MX05_292_0807EN
 Transport,assemblyandconnection

4.2.8 Mounting the The platform has two sections. The larger part of the platform is first
working platform fitted to the tubular column element when it is still lying horizontal, on
the side where the delivery pipes are installed.

MX05_291_0906EN 1

Lowering the platform

" Position the tubular column element in such a way that you can
fit the larger part of the platform.

" Raise the larger part of the platform.

" Lower the larger part of the platform over the tubular column
element. Make sure that the two pins (1) of the platform slide
into the guides (2).

" Secure the two pins (1) with one linch pin each.

MX05_291_0906EN 439
 Transport,assemblyandconnection

2
2

3
1

MX05_291_0906EN 2

Securing the platform

" Using the levers (2), push the two locking pins (1) into the
tubular column element.

" Secure the two levers (2) with one linch pin each (3).

" Fit the ladder elements underneath the platform, as described

on page 438.

440 MX05_291_0906EN
 Transport,assemblyandconnection

The smaller part of the platform is fitted to the tubular column when it
is standing vertically and then connected with the larger part of the
platform.

MX05_291_0906EN 3

Raising the tubular column

Note
Check the crane cable guide before raising the tubular column
element.

" Attach the lifting cables to the tubular column element.

" Guide the two chains in between the two handrail halves (1).

" Connect the two chains approx. 50cm beneath the handrail
using a shackle(2).

" Raise the tubular column element.

MX05_291_0906EN 441
 Transport,assemblyandconnection

MX05_291_0906EN 4

Placing a tubular column

" Place the tubular column element onto the cruciform base or
another tubular column element and connect it, as described
on page 428.

442 MX05_291_0906EN
 Transport,assemblyandconnection

MX05_291_0906EN 5

Attaching the platform

" Attach the smaller part of the platform to the larger part of the
platform and secure both connections with one linch pin (1)
each.

MX05_291_0906EN 443
 Transport,assemblyandconnection

4.2.9 Fitting the bottom If you are not using the stationary boom as a freestanding stationary
plates boom, you will require 4 bottom plates as sole plates and a minimum
of 8 corner brackets for supporting the tubular column in the holes in
the floor.
There must be at least two concreted floors with holes in the floor.

Danger
Please note the following points when using the stationary boom in
an operation which involves climbing.
 The foundation onto which the bottom plates are fitted must be
prepared according to requirements.
 The storey floors must be able to absorb the forces which are
induced via the corner brackets.
 The limit parameters must be observed.
If these are not observed, the boom may tip over or other damage
may be caused.

MX05_293_0810EN 1

Hole in floor

Hole in floor The holes in the floor must be square−shaped with a length along
each side of 1 m.

444 MX05_293_0810EN
 Transport,assemblyandconnection

" Fit the lower 9 m tubular column element to the climbing

column, as described on page 428.

" Fit the climbing system to the tubular column (which has been
pre−assembled), as described on page 436.

MX05_293_0810EN 2

Lowering the tubular column

Note
Make sure that the tubular column is correctly aligned. The delivery
line points in the direction of the construction site.

" Raise the pre−assembled tubular column and lower it down

through the holes in the floor.

MX05_293_0810EN 445
 Transport,assemblyandconnection

MX05_293_0810EN 3

Fitting the bottom plates

" Place the 4 bottom plates (1) in the correct position underneath
the tubular column.

" Fasten each of the 4 bottom plates with 6 anchor bolts.

446 MX05_293_0810EN
 Transport,assemblyandconnection

4.2.10 Fitting the corner Attach 4 corner brackets to each of the holes in the floor.
brackets

2
MX05_294_0807EN 1

Fitting the corner brackets

" Position the 4 corner brackets (1) in the corners of the holes
inthe floor.

" Fasten each of the 4 corner brackets (1) to the floor with an
anchor element (2).

MX05_294_0807EN 447
 Transport,assemblyandconnection

Placing the wedges

MX05_294_0807EN 2

Only use wedges in the upper and lower levels

" Drive 8 wedges (1) between the tubular column and the corner
brackets in the upper level.

" Drive 8 wedges (1) between the tubular column and the corner
brackets in the lower level.

Caution
During concreting operations and when the boom is in the rest posi
tion, the tubular column must only be fastened to the corner brackets
by wedges in two levels.
If you are using corner brackets in three levels, the tubular column
must only be wedged to the corner brackets in the upper and lower
level, otherwise the horizontal loads which are transferred to the
structure at this point will be excessive.

448 MX05_294_0807EN
 Transport,assemblyandconnection

4.2.11 Fitting the You can use the arm assembly either as a mobile boom or as a sta

arm assembly tionary boom. For information about how to do this, please also refer
to the Disassembly" section in the truck−mounted concrete pump
Operating Instructions.

Note
The following work steps only show the fitting of the arm assembly to
a stationary boom. You will need the truck−mounted concrete pump
Operating Instructions to use the arm assembly on a truck−mounted
concrete pump.

When working at height, use the climbing aids and working plat

forms provided for reasons of safety or wear a safety harness. The
relevant national regulations must be complied with.

MX05_306_0811EN 1

" Fold up the handrail (1) on the platform of the slewing cylinders
and secure it.

MX05_306_0811EN 449
 Transport,assemblyandconnection

MX05_306_0811EN 2

" Hook the ladder (1) for climbing onto the boom pedestal into
the platform of the slewing cylinders and secure it.

450 MX05_306_0811EN
 Transport,assemblyandconnection

Observe the following points when transporting the arm assembly

using a crane:
− Only use the appropriate lifting tackle.
− Balance the centre of gravity with the shortening claw (3) on the
transport chain so that the arm assembly hangs horizontally.
− Unhook the lifting tackle from the crane once transportation is
complete. Secure the cable to the arm assembly and stow the
transport chain and the shackles in the container (2).

3
4

MX05_306_0811EN 3

No. 0 Designation
1 Stationary boom pedestal
2 Transport chain container
3 Shortening claw
4 Lifting tackle (1 x cable, 2 x transport chain)
5 Arm assembly

MX05_306_0811EN 451
 Transport,assemblyandconnection

5 6 5 6
7 8 9

3 3

MX05_306_0811EN 4

No. 0 Designation
1 Truck−mounted boom pedestal
2 Stationary boom pedestal
3 Hydraulic hoses with bulkhead plate on the boom pedestal
4 Arm assembly
5 Slewing stop
6 Journal
7 Slewing head
8 Guide for slewing stop
9 Locating bolt

452 MX05_306_0811EN
 Transport,assemblyandconnection

MX05_306_0811EN 5

" Fold the bulkhead plate(1) for the hydraulic ports on the
boompedestal to one side.

" Place the arm assembly(2) such that the slewing head is
positioned on the journal.

MX05_306_0811EN 453
 Transport,assemblyandconnection

1 2

3
MX05_306_0811EN 6

" Insert the locating bolt(1) through the slewing stop and the
guide on the multi−boom adapter. Secure the locating bolt
using the spring pin (2).

" Repeat the procedure on the opposite side.

" Fold the bulkhead plate(3) upwards and secure it using

theconnecting bolt and spring pin.

454 MX05_306_0811EN
 Transport,assemblyandconnection

3
1

MX05_306_0811EN 7

" Unhook the lifting tackle from the crane and secure both
cables to the arm assembly using the shackle(1).

" Stow the transport chain(2) in the container(3) on the

slewinghead.

MX05_306_0811EN 455
 Transport,assemblyandconnection

Danger
When fitting the arm assembly, you must ensure that the hydraulic
lines are not mixed up as this could cause the arm assembly to
carryout incorrect movements as it is being controlled.
The connections for the hydraulic lines are identified by coloured
markings.

2
1

MX05_306_0811EN 8

Note
Check the coloured markings on the hydraulic hoses.

" Connect the hydraulic hoses from the bulkhead plate (1) of the
boom pedestal to the hydraulic ports of the boom with the
same coloured markings.

" Connect the electrical connector from the arm assembly to the
socket(2) on the bulkhead plate.

456 MX05_306_0811EN
 Transport,assemblyandconnection

Danger
When the boom is in operation, the handrail on the platform of the
slewing cylinders must be folded down, because when the handrail
is folded up, it protrudes into the slewing circle of the arm assembly.
Operating the boom when the handrail is folded up is prohibited,
because there is a risk of injury from falling components and the
stationary boom may be damaged.

MX05_306_0811EN 9

" After fitting the arm assembly, fold down the handrail (1) on the
platform of the slewing cylinders.

MX05_306_0811EN 457
 Transport,assemblyandconnection

MX05_306_0811EN 10

" Remove the ladder for climbing onto the boom pedestal and
secure it on the working platform as illustrated above.

458 MX05_306_0811EN
 Transport,assemblyandconnection

4.3 Stationary When pumping concrete, you must only use perfect and safe deliv

delivery line ery lines, couplings and seals. The delivery lines and couplings must
be specially designed for the pressure specified on the pump rating
plate. The delivery lines are subject to wear, which is dependent
upon:
− the concrete pressure
− the concrete composition
− the delivery line material.

10
9
8
7
6

5
4
3
2
1

MX05_199_0808EN 1

No. 1 Designation
1 Pressure pipe
2 Bolted coupling
3 Reducer
4 Clamp coupling
5 Pipe bracket
6 Delivery pipe (adapter pipe)
7 Clamp coupling
8 Pipe bracket
9 Vibration damper
10 Delivery pipe (adapter pipe)

MX05_199_0808EN 459
 Transport,assemblyandconnection

4.3.1 Danger zone

3m
MX05_199_0808EN 2

Danger zone for stationary delivery lines

Danger
Serious injuries may be caused by the delivery line bursting as a
result of a sudden increase in pressure.
Do not remain in the danger zone of a stationary delivery line.
Cover the stationary delivery line with a metal casing or timber
cladding if persons are working in its immediate vicinity.

MX05_199_0808EN 3

Cover delivery lines

460 MX05_199_0808EN
 Transport,assemblyandconnection

4.3.2 Instructions for The stationary delivery line can be laid horizontally over the ground,
laying the line or vertically or inclined against walls. The entire length of the delivery
line must be easily accessible and removable.

Note the following points when laying the delivery line:

" Lay the stationary delivery line without stresses.

" Support the delivery line so that couplings can be easily fitted
and removed. Double wooden chocks (see illustration) are
most suitable as they allow for longitudinal and latitudinal
movement by the delivery line.

MX05_199_0808EN 4

Support the delivery line with double wooden chocks

" Use highly wear−resistant pipes for sections which are difficult
to access.

" Begin laying the delivery line at the concrete pump as other

wise you will have to line up the concrete pump to the delivery
line.

MX05_199_0808EN 461
 Transport,assemblyandconnection

MX05_199_0808EN 5

Delivery line leading away at a right angle

to the concrete pump

" Route the stationary delivery line away from the concrete pump
at right angles to it. This minimizes the effect of pump pulsa

tions which may be transmitted from the delivery line to the
pump and vice versa.

" Guide the delivery line in the direction of the arrow away from
the concrete pump. The operator’s side of the concrete pump
is then not in the danger zone.

" Fit only as−new delivery pipes near the pump, as the concrete
pressure is highest here.

" Secure couplings against spontaneous opening.

" You must also take into account any components of the
delivery line required for distribution and cleaning such as
aT−delivery pipe with wash−out port, scraper pig gates,
diversion valves, gate valves etc.

462 MX05_199_0808EN
 Transport,assemblyandconnection

4.3.3 Fastening Pump pulsations occur when pumping concrete. These are caused
by the pump itself and are transmitted to the delivery line system.
The stationary delivery line must be safely secured and stabilised
onthe supporting ground.

Danger
There is a risk of serious injury from falling items.
Do not secure the stationary delivery line to reinforcements or scaf
folding as these can be moved and could collapse.
If you wish to secure the stationary delivery line to reinforcements or
scaffolding, check whether the scaffolding can bear the load.

Horizontal All horizontal delivery lines must be anchored on the supporting

delivery line ground.

" Use pipe brackets which are secured to a suitable supporting

ground capable of bearing the load.
å The pump pulsations are reduced and the delivery line is
prevented from bending.

MX05_199_0808EN 6

Fastening the delivery line

MX05_199_0808EN 463
 Transport,assemblyandconnection

Fixed point A fixed point is a 1−2m3 large, reinforced lump of concrete with a
delivery pipe secured to it or sealed inside it. It takes pump pulsa

tions from the delivery line.

" Install a fixed point near to the concrete pump.

å The pump pulsations are reduced and the delivery line is
prevented from bending.

MX05_199_0808EN 7

Elasticity of the delivery line using a fixed point

464 MX05_199_0808EN
 Transport,assemblyandconnection

Vertical (angled) Vertical or angled delivery lines leading upwards or downwards must
delivery line always be fastened to the structure or background so that they are
self−supporting. The delivery line must not be supported by the
lowest elbow.

MX05_199_0808EN 8

Fastening the delivery line

The lowest elbow should be a thick−walled 90° cast elbow with a

radius of 1m.

MX05_199_0808EN 465
 Transport,assemblyandconnection

Risers The delivery line is called a riser where it is laid in such a way that
the concrete is pumped upwards.

Gate valve The weight of the concrete in the riser exerts a force on the concrete
pump (approximately 30kg per metre of continuous pipe) when the
pump is switched off.

" Install a gate valve at the start of the riser.

å The delivery line can be closed off so that the pressure
bears on the gate valve and not on the concrete pump.

Downpipes The delivery line is called a downpipe if it is laid in such a way that
the concrete is pumped downwards.

Gate valve The concrete flows down through the delivery line under its own
weight when the pump is switched off. This causes the concrete
column to break off and the concrete can segregate.

" Install a gate valve at the end of the downpipe.

å The delivery line can be closed off so that the concrete
cannot flow out of the delivery line.

466 MX05_199_0808EN
 Transport,assemblyandconnection

4.3.4 SK delivery line When laying Putzmeister SK delivery pipes, maintain a gap of 4mm
system between the individual pipes.

Note
Grease all couplings and seals well internally before assembly.
Usea lithium soap base multipurpose grease labelled K2K.

4mm

MX05_199_0808EN 9

Putzmeister SK delivery line with clamp coupling, A seal and spring pin

" Secure each clamp coupling with a spring pin.

MX05_199_0808EN 467
 Transport,assemblyandconnection

4.4 Connection In order to be able to use the placing boom on the construction site,
you must connect the delivery line to a concrete pump, have the
hydraulic pack connected to the electrical power supply and set up
the cable remote control for use.
If the placing boom has a squeeze valve, the air hose must be
connected to a compressed air system.

4.4.1 Connecting the Before putting the boom into service for the first time, you must
delivery line to the connect a delivery line to the elbow on the boom pedestal.
boom pedestal

468 MX05_331_1008EN
 Transport,assemblyandconnection

Note
Grease all couplings and seals well internally before assembly.
Usea lithium soap base multipurpose grease labelled K2K.

4mm

MX05_331_1008EN 1

The spacing is set automatically by the triple−lip seal

" Push a triple−lip seal over either end of the adapter pipe.

" Insert the adapter pipe between the delivery line on the tubular
column and the elbow on the boom pedestal.

" Push the triple−lip seal over the weld−on rings.

" Fasten the adapter pipe to the ladder hooks using the pipe
brackets.

" Fit the couplings and secure them.

MX05_331_1008EN 469
 Transport,assemblyandconnection

Stationary delivery line

Note
Make sure that the spacing to the elbow on the boom pedestal is
4mm if you connect a stationary delivery line.

MX05_331_1008EN 2

Connecting the stationary delivery line

No. 1 Designation
1 Elbow on the boom pedestal
2 Stationary delivery line

470 MX05_331_1008EN
 Transport,assemblyandconnection

Note
Grease all couplings and seals well internally before assembly.
Usea lithium soap base multipurpose grease labelled K2K.

4mm

MX05_331_1008EN 3

" Push a triple−lip seal over the end of the delivery line.

" Push the triple−lip seal over the weld−on rings.

" Fit the coupling and secure it.

MX05_331_1008EN 471
 Transport,assemblyandconnection

MX05_331_1008EN 4

Do not ascend the ladder during pumping operations.

Danger
Heavily worn delivery lines can burst at any time under high operating
pressure (e.g. in the event of blockages). For this reason, ascending
the ladder during pumping operations is forbidden.

472 MX05_331_1008EN
 Transport,assemblyandconnection

4.4.2 Electrical connection The power on the construction site must be supplied from a special
feed point (construction site power distribution point).

9
7

6 5 4 3
MX05_331_1008EN 5

Electrical connections schematic

No. 1 Designation
1 Supply cable from the site power distribution point
3 Control cabinet
4 Cable remote control
5 Climbing cylinder remote control
6 Pump control cabinet
7 Chain hoist remote control
8 Chain hoist
9 Boom control block

MX05_331_1008EN 473
 Transport,assemblyandconnection

High voltage
Work on electrical systems and equipment must be carried out only
by a qualified electrician or by instructed persons under the super
vision and guidance of a qualified electrician and in accordance with
electrical engineering rules and regulations.

Caution
Attention must be paid to the direction of rotation when connecting
the electric motor (see information plate on the casing). The hydraulic
pump or hydraulic system may be damaged if the direction of rotation
is incorrect.

" Have a supply line connected to the control cabinet. The

supply line must be made using a 5x6 mm2 rubber−insulated
flexible cable and a 32ampere CEE 5pin standard connector.

" Have the supply cable connected to the site power distribution
point.

" Unbolt the guard over the electric motor so that you can see
the fan wheel of the electric motor to allow you to check the
direction of rotation of the electric motor.

474 MX05_331_1008EN
 Transport,assemblyandconnection

MX05_331_1008EN 6

Switching off the main switch

" Switch the main switch on the control cabinet to Off.

MX05_331_1008EN 7

Plugging in the supply cable

" Plug the supply cable in at the control cabinet.

MX05_331_1008EN 475
 Transport,assemblyandconnection

4.4.3 Connecting the You must connect the cable remote control in order to be able to
cable remote control switch on the electric motor.

" Press the EMERGENCY STOP button on the remote control.

The machine may otherwise execute unintended movements
as soon as the main switch is switched on.

MX05_331_1008EN 8

Connecting the cable remote control to the control cabinet

" Plug the cable remote control connector into the connector
socket on the control cabinet and secure it.

" Plug the second connector into the remote control and
secureit.

476 MX05_331_1008EN
 Transport,assemblyandconnection

MX05_331_1008EN 9

Switching on the main switch

" Switch the main switch on the control cabinet to On.

" You will have to unlock the EMERGENCY STOP button by

turning it and sound the horn to begin operating the machine.

Caution
Carry the remote control in such a way that no control elements can
be actuated unintentionally. Do not damage the remote control
cable. Malfunctions may otherwise occur.
Never put the remote control down when the machine is in ready
mode. If this is not possible in exceptional cases, press the EMERG
ENCY STOP button, disconnect the remote control and lock the
remote control unit away.

MX05_331_1008EN 477
 Transport,assemblyandconnection

" Switch the motor on briefly and off again using the remote
control unit.

" Observe the fan wheel. You will be able to determine the
direction of motor rotation as soon as the fan slows down.

Note
You must have a qualified electrician swap the phases at the feed
connector socket if the direction of rotation does not coincide with
the direction of the arrow.

" Finally, refasten the cover on the electric motor.

478 MX05_331_1008EN
 Transport,assemblyandconnection

4.4.4 Connecting the In order to be able to start the squeeze valve, you must connect the
air hose air line on the boom to a compressed−air supply line.

Caution
The squeeze valve is supplied with compressed air from the construc
tion site. You must ensure that the compressed−air supply line is de
pressurized before you connect the valve.

MX05_331_1008EN 10

Connecting the air hose

" Depressurize the compressed−air supply line.

" Connect the compressed−air supply line to the air hose (1).

MX05_331_1008EN 479
 Transport,assemblyandconnection

4.5 Removal Please also refer to the Assembly" section in the truck−mounted
concrete pump Operating Instructions for further information.

You need to do the following to disassemble the arm assembly from

the stationary boom
− position the folded arm assembly to the horizontal,
− remove the delivery line from the boom pedestal,
− disconnect the remote control;
− isolate the control cabinet from the power supply.

MX05_307_0810EN 1

" Disconnect the electrical connection(1) from the bulkhead

plate(2) and connect it to the blank socket on the arm
assembly.

" Disconnect the hydraulic lines at the quick mounting couplings

on the bulkhead plate.

" Fold the bulkhead plate to one side.

" Open the delivery line on the upper end of the riser.

480 MX05_307_0810EN
 Transport,assemblyandconnection

MX05_307_0810EN 2

" Remove the locating bolt(1) from the multi−boom adapter and
refit it in the empty bore. Secure the locating bolt using the
spring pin(2).

" Repeat the procedure on the opposite side.

MX05_307_0810EN 481
 Transport,assemblyandconnection

MX05_307_0810EN 3

" Carefully hoist the arm assembly from the boom pedestal using
the lifting tackle secured to the arm assembly.

482 MX05_307_0810EN
 Transport,assemblyandconnection

4.5.1 Lowering the arm assembly onto the transport frame

1
2

MX05_307_0810EN 4

Lowering the arm assembly onto the transport frame

" Secure the arm assembly on the transport frame using the
pins(1).

" Secure the transport trestle to the lowest arm of the arm
assembly(2).

MX05_307_0810EN 483
 Transport,assemblyandconnection

4.5.2 Removing the boom pedestal from the tubular column

Danger
Before removing the pins which connect the boom pedestal to the
tubular column, the boom pedestal must be supported by crane.
After removing the pins, the boom pedestal may tip away from the
tubular column.

Note
Excessive tension on the crane cable will make it impossible to
remove the pins.
For the removal of the boom pedestal, the pins must not be under
tension.

MX05_307_0810EN 5

Removing the boom pedestal from the tubular column

" Release and remove the pins (1).

484 MX05_307_0810EN
 Transport,assemblyandconnection

4.5.3 Lowering the boom pedestal onto the transport frame

MX05_307_0810EN 6

Set the boom pedestal down on the transport frame and secure it

" Lift the boom pedestal together with the arm assembly from the
tubular column and set it down on the transport frame.

" Secure the boom pedestal with the four pins (1).

MX05_307_0810EN 485
 Transport,assemblyandconnection

Note
The procedure for disassembly is the reverse sequence of that for
assembly.

4.5.4 Removing the The platform has two sections. The smaller part of the platform is first
working platform removed from the tubular column while the column is still standing
vertically.

MX05_297_0810EN 1

Removing the working platform

" Attach the smaller part of the platform to a crane.

" Unlock the smaller part of the platform.

" Lift the smaller part of the platform down from the tubular
column.

486 MX05_297_0810EN
 Transport,assemblyandconnection

4.5.5 Disassembling the

tubular column
Note
The following operations are presented in order to show an example
of disassembling the uppermost element of the tubular column. The
rest of the tubular column is disassembled in a similar way.

Danger
Before removing the pins which connect the tubular column elements,
the tubular column must be supported by crane.
Otherwise, the tubular column element may tip away from the tubular
column once the pins are removed.

Note
Excessive tension on the crane cable will make it impossible to
remove the pins.
For the removal of the boom pedestal, the pins must not be under
tension.

MX05_297_0810EN 2

Disassembling the tubular column

" Release and remove the four pins (1).

MX05_297_0810EN 487
 Transport,assemblyandconnection

MX05_297_0810EN 3

Raising the tubular column

" Raise the tubular column and lay it down in such a way that
you can remove the larger part of the platform and the ladder
elements.

488 MX05_297_0810EN
 Transport,assemblyandconnection

2
2

3
1

MX05_297_0810EN 4

Removing the working platform

" Release the two levers (2).

" Using the levers (2), push the two locking pins (1) out of
thetubular column element.

" Attach the larger part of the platform to a crane.

" Lift the larger part of the platform down from the tubular
column.

MX05_297_0810EN 489
 Transport,assemblyandconnection

4.5.6 Removing the

ladder elements

MX05_297_0810EN 5

Removing a ladder element

" Unlock the ladder element.

" Push the ladder element out of the holders.

490 MX05_297_0810EN
 5 Operation

In this chapter you will find information on the operation of the machine.
It explains what operations are necessary for commissioning, moving
the boom, climbing and dismantling.

MX07_001_9408EN
 Operation

5.1 Commissioning You must make yourself so familiar with the machine when you take it
over that damage and accidents cannot occur.
Every time you use the machine you are taking on full responsibility
for the safety of persons within the machine’s danger zone. You are
therefore obliged to ensure that the machine is absolutely safe in
operation.

5.1.1 Functional fluids

10000700

Water, oil and fuel levels

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

" Check the hydraulic fluid level and top it up if necessary.

Note
The boom pedestal must be horizontal before the fluid level is
checked.

MX07_002_9503EN 51
 Operation

5.1.2 Function checks You should check the following functions before you begin using the
machine on the construction site.

Filter functions Dirty filters reduce the fluid flow considerably so that damage may
occur in the hydraulic system.

Vacuum meter for

the suction filter

MX07_003_0905EN 1

Vacuum meter

Note
You will have to replace the filter element if the indicator on the
vacuum meter is in the red zone at a fluid temperature of more
than30° C.

Environmental protection
Comply with the waste disposal regulations in force for your area
when changing the fluid filter.

52 MX07_003_0905EN
 Operation

Boom filter

MX07_003_0905EN 2

Pressing down the red button

" Bring the hydraulic fluid up to operating temperature

(u 50 °C).

" Press in the red button on the filter if it is sticking out.

Note
You must replace the filter element if the red button pops out again
after a short time.
The filter is OK if the red button remains depressed.

Environmental protection
Comply with the waste disposal regulations in force for your area
when changing the fluid filter.

MX07_003_0905EN 53
 Operation

EMERGENCY STOP It is only possible to intervene quickly in the event of danger if all
function EMERGENCY STOP buttons are functioning correctly.

Caution
The machine is no longer safe in operation if one of the EMERG
ENCY STOP buttons is defective, as you will no longer be able to
switch the machine off quickly enough if danger threatens.
You must therefore inspect the function of the EMERGENCY STOP
buttons and the lever position for the boom valves (see
Function
check on the boom control block") before starting work each time.

Danger
The machine is only switched off electrically when the EMERGENCY
STOP button is pressed. Although this causes all the electrically
actuated hydraulic valves to be switched off, an uncontrolled sinking
of the boom caused by leakages in the hydraulic system, for instance,
cannot be prevented in this way.

In no event should you first press the EMERGENCY STOP button if

the boom starts uncontrolled movements. Should you do this you will
have no ability to counteract the movement.

Furthermore, the EMERGENCY STOP circuit has no influence on the

accumulator pump and the agitator pump, i.e. the accumulator is
filled and the agitator continues to rotate, despite the EMERGENCY
STOP button having been pressed.

54 MX07_003_0905EN
 Operation

EMERGENCY STOP
button

MX07_003_0905EN 3

Press − lock EMERGENCY STOP

Turn − unlock EMERGENCY STOP

" Actuate the boom through the remote control.

" Press the EMERGENCY STOP button.

The boom must come to a halt immediately.

MX07_003_0905EN 55
 Operation

Function check on the You may only operate the machine if the boom control block is fully
boom control block functional.

" Switch on the radio or cable remote control.

" Operate the boom control levers briefly several times while
observing the levers on the boom control block.
å The lever for the boom valve operated and the lever for
theoperating mode selector valve must move each time.

Note
As soon as you release the boom control levers on the remote
control unit, the levers for the boom arm valves previously actuated
and for the operating mode selector valve must return to the central
position (zero position).

The reactions of the operating mode selector valve on the boom

control unit are delayed by some 3seconds if you use the cable
remote control.

56 MX07_003_0905EN
 Operation

Function check for You may only operate the machine if the emergency operation is fully
emergency operation functional.

MX07_003_0905EN 4

Switch the toggle switch to Local control"

" Switch the Local control − 0 − Remote control" toggle switch

on the control cabinet to Local control".

MX07_003_0905EN 5

Deactivate the EMERGENCY STOP circuit

" Press the Horn" toggle switch on the control cabinet.

The EMERGENCY STOP circuit is now deactivated. You can start

themotor.

MX07_003_0905EN 57
 Operation

MX07_003_0905EN 6

Starting the motor

" Start up the motor using the Motor On−Off" toggle switch.

MX07_003_0905EN 7

Press − lock EMERGENCY STOP

Turn − unlock EMERGENCY STOP

" Press the EMERGENCY STOP button on the control cabinet.

The motor must come to a halt immediately.

58 MX07_003_0905EN
 Operation

5.1.3 Remote control Depending on your machine’s equipment, you will be able to operate it
− with the radio remote control,
− with the cable remote control or
− directly on the machine in emergency operation

Hazard warnings The hazard warnings below are true for all types of remote control.

Danger
Before starting to use the remote control, press the EMERGENCY
STOP button on the remote control and set all control and monitoring
devices on the remote control to the
0" position. The boom may
otherwise execute unintended movements as soon as the remote
control is enabled.

Set the boom speed toggle switch to the
Slow" switch position and
turn the rotary controller to
0", before you begin to use the remote
control. This ensures that initial boom movements after the remote
control is activated are executed slowly to allow you to become
accustomed to the movement.

Caution
Carry the remote control in such a way that no control elements can
be actuated unintentionally. Do not damage the remote control
cable. Malfunctions may otherwise occur.
Never put the remote control down when the machine is in ready
mode. If this is not possible in exceptional cases, press in the
EMERGENCY STOP button, disconnect the remote control and lock
the remote control unit away.

MX07_207_0905EN 59
 Operation

Cable remote control You can only execute boom movements in black and white with the
cable remote control, i.e. the boom always moves at its maximum
speed, no matter how much you move the boom control lever.

Danger
Black−and−white control can lead to jerky movements and significant
swaying of the boom, which represents a high risk of an accident to
the operator guiding the hose. Set the toggle switch to the
Slow"
switch position and turn the rotary controller to
0", before you begin
to use the remote control.

MX07_207_0905EN 1

Toggle switch and rotary controller for adjusting boom speed

510 MX07_207_0905EN
 Operation

Starting up You must proceed as follows to start operations with the machine
using cable remote control:

MX07_207_0905EN 2

Switching off the main switch

" Switch the main switch on the control cabinet to Off.

" Press the EMERGENCY STOP button on the remote control.

The machine may otherwise execute unintended movements
as soon as the main switch is switched on.

MX07_207_0905EN 3

Connecting the cable remote control to the control box

" Plug the cable remote control connector into the connector
socket on the control cabinet and secure it.

" Plug the second connector into the remote control and
secureit.

MX07_207_0905EN 511
 Operation

MX07_207_0905EN 4

Switching on the main switch

" Switch the main switch on the control cabinet to On.

" You must unlock the EMERGENCY STOP button by turning it,
sound the horn and switch on the electric motor to operate the
machine.

512 MX07_207_0905EN
 Operation

Boom speed You can adjust the boom speed set in the works to any speed by
means of the boom speed rotary controller.

The procedure for adjusting the speed of boom movement is as

follows:

MX07_207_0905EN 5

Toggle switch and rotary controller for adjusting boom speed

" Press the EMERGENCY STOP button on the remote control.

" Set the toggle switch to the Slow" switch position.

" Turn the rotary controller to 0".

" Switch on the cable remote control.

" Set the boom speed required by trial and error using the rotary
controller.

MX07_207_0905EN 513
 Operation

5.2 Emergency operation In the event of failure of the cable remote control or the radio remote
control, you can operate the placing boom in emergency mode from
the boom control block.

You must proceed as follows:

MX07_141_0905EN 1

Switch the toggle switch to Local control"

" Switch the Local control − 0 − Remote control" toggle switch

on the control cabinet to Local control".

Note
The EMERGENCY STOP circuit is activated automatically when you
switch over from remote to local control. You must operate the horn
to deactivate the EMERGENCY STOP circuit.

514 MX07_141_0905EN
 Operation

MX07_141_0905EN 2

Deactivate the EMERGENCY STOP circuit

" Press the Horn" toggle switch on the control cabinet.

The EMERGENCY STOP circuit is now deactivated. You can start

themotor.

MX07_141_0905EN 3

Starting the motor

" Start up the motor using the Motor On−Off" toggle switch.

You may now operate the placing boom from the boom control block.

MX07_141_0905EN 515
 Operation

5.3 Boom movements You must have read the safety regulations before you extend the
placing boom.

Prohibited activities

MX07_004_0905EN 1

Prohibited

Danger
Avoid the following actions. They overload the placing boom and will
lead to damage and jeopardize persons:
 lifting and transporting loads;
 allowing the placing boom to strike an obstacle;
 pushing with the placing boom in order to move an obstacle out of
the way, for instance;
 tearing away a trapped end hose by force.

516 MX07_004_0905EN
 Operation

5.3.1 Restrictions on use Extreme weather conditions, such as gales, storms or low tem

peratures restrict the use of the boom, or can even make its use
impossible.

Bad weather Shift the placing boom to the rest position in the event of storms
and storms andbad weather.
− Booms with a vertical reach of 42m or more (M42 and larger)
may only be operated in wind forces up to7
(windspeed61km/h=17m/s).
− Booms with a vertical reach of less than 42m (< M42) may only
be operated in wind forces up to8
(windspeed74km/h=20m/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
element. There is a risk of lightning strike in the event of storms.

Tower cranes on construction sites generally have wind speed

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 force 7 and greater, green leaves break from trees and
inconvenience is felt when walking against the wind.
− In winds of force8 and greater, small branches break from trees
and walking outside is significantly impeded.

Cold weather The boom must not be used in temperatures below minus 15_C
(+5_F). There is a danger of damage to the steel (brittle fracture)
and the seals throughout the system at such extreme minus tem

peratures.

In addition, such minus temperatures should be considered the

realistic 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.

MX07_004_0905EN 517
 Operation

5.3.2 Danger zone

22001100

The danger zone when working with the boom is the zone over
which the boom is slewed.

Falling items
There is a risk of injury from parts of the delivery line falling beneath
the slewing circle of the placing boom. There is a risk of injury from
falling concrete beneath the end hose.
You should therefore secure the danger zone. Keep the danger zone
under constant observation.
You must halt work immediately and press the EMERGENCY STOP
button if anyone enters the danger zone.

518 MX07_004_0905EN
 Operation

High–voltage lines A spark can jump across from high−voltage lines even if you just
approach them and this will energize the machine and the surround

ing area. You must therefore always maintain the specified safe
clearance.

MX07_004_0905EN 2

Caution in the vicinity of high−voltage lines

Rated voltage [V] Safe clearance [m]

up to 1 kV 1.0

1 kV to 110 kV 3.0

110 kV to 220 kV 4.0

220 kV to 380 kV 5.0

unknown rated voltage 5.0

MX07_004_0905EN 519
 Operation

Overlapping working
ranges

22001400

Beware of overlaps

Caution
Take note of the working ranges of other construction plant
(e.g.cranes, other concrete placing booms, etc).

Signalling boom
movements

MX07_004_0905EN 3

Sound the horn first, then move

Note
Move the placing boom with cautious operation of the controls.
Maintain visual contact with the placing site.
Warn by sounding the horn before you move the boom.

520 MX07_004_0905EN
 Operation

Hand signals

10000331

See the Hand signal for boom and pumping operations" chapter for hand signals

Danger
Move the placing boom only if you can see all of the working range.
If this is not possible, you must only move the placing boom in
response to signals from a signaller.
Agree unambiguous hand signals with the signallers.

MX07_004_0905EN 521
 Operation

5.3.3 Spontaneous retrac- The hydraulic fluid heats up to an average temperature of 60°−70° C
tion of the boom during operation because of the friction in the lines.
cylinders When the hydraulic fluid cools, its volume reduces as cold hydraulic
fluid has a smaller volume than does hot hydraulic fluid. Conse

quently, the boom cylinders retract slightly and the boom sinks.

Caution
The boom can sink during lengthy pauses in work due to cooling of
the hydraulic fluid. For this reason, you must never leave the boom
unattended in the extended position during breaks in work.

Loss of volume

12300102

Sinking of the boom due to loss of volume of the hydraulic fluid on cooling

The amount by which the boom sinks depends on the extent to

which the individual boom cylinders have been extended and the
magnitude of the temperature difference in the hydraulic fluid.

522 MX07_004_0905EN
 Operation

5.3.4 Uncontrolled boom The following defects may be the cause of uncontrolled boom
movements movements:
− Malfunction in the remote control circuit
− Malfunctions on the boom control block
− Lines, threaded unions or boom cylinders leaking
− Defective mono−isolator on the boom cylinder
− Hydraulic system not carefully bled
− Insufficient hydraulic fluid in the reservoir
− Cooling of the hydraulic fluid

In this case, the boom may move as soon as the remote control is
switched on. Halt work immediately. You can continue working only
after the causes have been remedied and perfect functioning of the
machine is ensured.

Note
Whatever the reason for the uncontrolled movements of the boom,
you must halt the work on site and have the cause of the breakdown
determined and rectified by qualified personnel.

Danger
In no event should you first press the EMERGENCY STOP button if
the boom starts uncontrolled movements. Should you do this you will
have no ability to counteract the movement.

Countermeasures You must proceed as follows if the boom starts uncontrolled

movement:

" Counter the uncontrolled movement immediately and attempt

to steer the boom out of the danger zone and bring it to rest
under control.

If the uncontrolled boom movement continues, despite counter

measures:

" Press the EMERGENCY STOP button.

Note
Repeated practice is required to ensure that it will be possible to
implement the measures described above in an emergency.

MX07_004_0905EN 523
 Operation

5.4 Hand signals for Pump operators and persons guiding them must agree unambigu

boom and pumping ous hand signals before commencing work. Suggestions for the
operations most important hand signals are made in this chapter. They are
based on DIN24081, DIN 33409 and guideline RI/08.90/2 issued by
the German Construction Employers’ Liability Insurance Association,
amongst other guidelines. The direction of movement is specified
from the machine operator’s direction of view.

EMERGENCY STOP Extend both arms outwards

and move up and down quickly.

10000308

Stop Extend both arms out

totheside.

10000306

Slow Place a fist on the helmet.

10000307

524 BP07_006_0904EN
 Operation

Slew boom to the left One arm points in the

slewingdirection.

10000309

Slew boom to One arm points in the

the right slewingdirection.

10000310

Arm 1 up One arm hangs vertically

downwards. The other arm
points upwards with the thumb.

10000311

Arm 1 down One arm hangs vertically

downwards. The other arm
points downwards with the
thumb.

10000312

BP07_006_0904EN 525
 Operation

Arm 2 up One arm points downwards at

an angle. The other arm points
upwards with the thumb.

10000313

Arm 2 down One arm points downwards at

an angle. The other arm points
downwards with the thumb.

10000314

Arm 3 up One arm points horizontally to

the side. The other arm points
upwards with the thumb.

10000315

Arm 3 down One arm points horizontally to

the side. The other arm points
downwards with the thumb.

10000316

526 BP07_006_0904EN
 Operation

Arm 4 up One arm points upwards at an

angle. The other arm points
upwards with the thumb.

10000317

Arm 4 down One arm points upwards at an

angle. The other arm points
downwards with the thumb.

10000318

Arm 5 up One arm points vertically up

wards. The other arm points
upwards with the thumb.

10000319

Arm 5 down One arm points vertically up

wards. The other arm points
downwards with the thumb.

10000320

BP07_006_0904EN 527
 Operation

End hose forwards Move both crooked arms

forwards and backwards.
Thepalms of the hands face
inwards towards the person
giving directions.

10000321

End hose back Move both crooked arms

forwards and backwards.
Thepalms of the hands face
away from the person giving
directions.

10000322

End hose to the left Both arms point in the direction

of movement for the end hose.

10000323

End hose to the right Both arms point in the direction

of movement for the end hose.

10000324

528 BP07_006_0904EN
 Operation

End hose up Move both crooked arms up

wards and downwards with the
thumbs pointing upwards.

10000325

End hose down Both arms move up and down.

Both index fingers point down

wards.

10000326

Increase output/ The thumb of one hand points

Start pumping upwards. The palm of the other
hand is held over it.

10000327

Reduce output The thumb of one hand points

downwards. The palm of the
other hand is held under it.

10000328

BP07_006_0904EN 529
 Operation

Reverse pumping The crooked elbow of one arm

points downwards into the palm
of the other hand.

10000329

Stop pumping Grip both hands together over

the head.

10000330

530 BP07_006_0904EN
 Operation

5.5 Unfolding the The following procedure is an example of how to unfold the arm
4 Z boom assembly. The boom must be folded in the reverse sequence.

Caution
Always observe the specified sequence for unfolding and folding the
boom. Failure to comply with the sequence may allow the crank lever
in the C hinge to compress the delivery line, adjacent hydraulic cylin
ders or other components.

Danger

MX07_208_0810EN 1

Arms3 and4 must not be moved behind the C hinge when unfolded
or partially unfolded during the entire boom operation. In this arm
position, the rod side C cylinder hydraulic pressure is so high that
the pressure limiting valve responds and the boom will gradually
slump.

There is also the risk that arm3 may slump uncontrollably if the arm
assembly is folded in or out any further.

MX07_208_0810EN 531
 Operation

5.5.1 Rest position The boom is vertical in the rest position.

MX07_208_0810EN 2

532 MX07_208_0810EN
 Operation

5.5.2 Unfolding sequence The arm assembly is equipped with three retaining hooks. The retain

ing hooks must be relieved so that they can unlock automatically.
Pull the arm assembly together briefly to relieve the retaining hooks.

Caution
The hydraulic fluid is warm when you fold the arm assembly. It then
cools and the pressure in the cylinder drops. When you lift arm1,
theremaining arms relax and press on the retaining hook.

Pulling the arm

assembly together –
relieving the retaining
hooks

MX07_208_0810EN 3

" Drop arm2 and arm4 briefly.

" Raise arm3 briefly.

" Check whether the retaining hooks (1) have been unlocked.

MX07_208_0810EN 533
 Operation

Arm 2

45°

MX07_208_0810EN 4

Raising arm 2

" Unfold arm 2 approximately 45_.

Arm 1

MX07_208_0810EN 5

Lowering arm 1

" Lower arm 1 until arm2 is vertical.

534 MX07_208_0810EN
 Operation

Caution
Before you unfold arm3, you must open arm4 through approxi
mately 15_, so that the boom tip is approximately 1m away from the
C hinge (hinge between arm2 and arm3). The crank lever on the
Chinge will be forced against the elbow at the boom tip if you do not
follow this instruction.

Arm 4

15°

MX07_208_0810EN 6

Unfolding arm 4

" Open arm4 approximately 15_.

MX07_208_0810EN 535
 Operation

Arm 3

45°

MX07_208_0810EN 7

Unfolding arm 3

" Unfold arm3 approximately 45°.

Arm 4

MX07_208_0810EN 8

Unfolding arm 4

" Unfold arm 4 enough to allow you to unlock the end hose.

536 MX07_208_0810EN
 Operation

End hose

12500401

Unlocking the end hose

" Unlock the end hose by pulling the two locking levers
downwards.

MX07_208_0810EN 9

Unlocking the end hose

MX07_208_0810EN 537
 Operation

5.5.3 Impermissible
working range

MX07_111_0505EN 1

1 Range in which work with the end hose is not permitted

Caution
The end hose may not be shifted behind the vertical of the boom.

538 MX07_111_0505EN
 Operation

5.6 Pumping operations Before you begin pumping you must have carefully completed the
operations for making the machine ready and setting up the tubular
column and have shifted the placing boom into the working position
required. Make sure that your machine is operating perfectly before
you fill the hopper with concrete and pump it through the delivery
line.

Danger
Entrapped air in the delivery line is dangerous as the compressed air
is released suddenly at the end of the delivery line and the concrete
can be blown out explosively. No air must be sucked in for this
reason.
You should therefore always fill the hopper with concrete up to the
mixer shaft during pumping operations.

MX07_146_0905EN 1

Danger from escaping compressed air

MX07_146_0905EN 539
 Operation

5.6.1 Boom The boom can bounce if air is sucked in and compressed in the
delivery line. You should therefore always make sure that no air is
sucked in.

If the placing boom sinks without the control device being actuated,
this may mean that the safety or check valve in one of the boom
cylinders is leaking. You should call our After Sales Department
immediately if this is the case.

The boom may sink during lengthy breaks in pumping as a result of

cooling of the hydraulic fluid.

540 MX07_146_0905EN
 Operation

Favourable boom
position

MX07_146_0905EN 2

Last arm horizontal

Note
A horizontal position of the last arm is favourable for pumping.

If the last arm is lower than the horizontal, the concrete in this part of
the delivery line will flow more quickly as a result of its self−weight.
The flow velocity is lower if the arm position is horizontal, and thus
the wear on the delivery pipes and the end hose is less.

When the pump is stopped, only the content of the end hose flows
out if the arm position is horizontal; the content of the delivery line
can flow out if the arm position is below the horizontal.

The strokes of the pump cause forces to act along the delivery line
and thus along the boom. If the last arm is vertical, the forces also
act vertically on the boom end and move the boom up and down.
Ifthe arm position is horizontal, the boom is moved forwards and
backwards, which causes a light rocking motion.

MX07_146_0905EN 541
 Operation

5.6.2 End hose Observe the safety regulations when working with the end hose.

Danger zone

2 MX07_146_0905EN 3

The danger zone when starting to pump and during washing

out procedures is the area around the end hose in which the
end hose can strike out. The diameter of the zone is twice the
end hose length.
1 End hose length, max. 4 m
2 Danger zone = 2 ×#end hose length = 8 m

Danger
There is a risk of injury in the area around the end hose if the end
hose strikes out when starting to pump, after a blockage has been
freed or during washing out. This zone is twice the end hose length
in diameter.
The end hose must be allowed to hang freely.
Ensure that no−one is standing in the danger zone. Keep the danger
zone under constant observation.
You must stop working immediately and press the EMERGENCY
STOP button if anyone enters the danger zone.

542 MX07_146_0905EN
 Operation

MX07_146_0905EN 4

Danger
Never bend the end hose over. Never attempt to straighten a bent
end hose by increasing the pressure. The end hose must not be in
serted in the concrete. Extension of the placing boom and end hose
beyond the length specified on the boom rating plate is forbidden.
The end hose must be secured against falling.

MX07_146_0905EN 543
 Operation

Use of a delivery hose End hoses must not be fitted with any extension coupling, outlet
with flow restrictor shoes or other dangerous outlet fitting. You can use the modified
Putzmeister delivery hose with flow restrictor if you wish nevertheless
to achieve a uniform flow of the concrete for filling hollow blocks.

ÂÂÂÂ
Products supplied
ÂÂÂÂ
ÂÂÂÂ
ÂÂÂÂ
ÂÂÂÂ
ÂÂÂÂ
ÂÂÂÂ
1

ÂÂÂÂ
ÂÂÂÂ
ÂÂÂÂ
2

3 ÂÂÂÂ
4

MX07_146_0905EN 5

1 Rubber protective sleeve

2 Modified delivery hose
3 Push−in spout
4 Flow restrictor

Danger
The delivery hose with flow restrictor may only be used for filling hol
low blocks. The rubber protective sleeve must always be pulled fully
down over the push−in spout, whether or not you are using the flow
restrictor. The delivery hose may no longer be used if the protective
sleeve is damaged or missing entirely.

544 MX07_146_0905EN
 Operation

Use of a squeeze The squeeze valve is used to close off the delivery line above the
valve end hose during brief breaks in pumping to prevent concrete run

ning out of the delivery line. This is particularly useful in applications
such as
− concreting of foundations or
− underwater concrete placement or
− in jobs where the concrete must be precisely dosed".

Danger zone

3 MX07_146_0905EN 6

Danger zone
1 Length of the squeeze valve = 1 m
2 End hose length, max. 3 m
3 Danger zone is:
2 x end hose length + 2 x length of the squeeze valve = 8 m

Danger
Connect only a 3m end hose to the squeeze valve.

Danger
There is a risk of injury in the area around the end hose if the end
hose strikes out when starting to pump, after a blockage has been
freed or during washing out. The diameter of this zone is twice the
end hose length plus twice the length of the squeeze valve.
The end hose must be allowed to hang freely.
Ensure that no−one is standing in the danger zone. Keep the danger
zone under constant observation.
You must stop working immediately and press the EMERGENCY
STOP button if anyone enters the danger zone.

MX07_146_0905EN 545
 Operation

Activating
Squeeze
valve" function 1

2 3

MX07_146_0905EN 7

1 Squeeze valve control panel

2 Squeeze valve On/Off" toggle switch
3 Remote control

Note
The squeeze valve will only close as soon as the pump is switched
off at the remote control using the
Pump On/Off" toggle switch if the

Squeeze valve" function on the control panel is activated. The
squeeze valve opens as soon as you re−start the pump.

" Switch the pump off at the remote control.

" Push the Squeeze valve On/Off" toggle switch on the control
panel up.
å This activates the Squeeze valve" function and the
squeeze valve closes.

Note
When the
Squeeze valve" function is activated, the pump will only
begin to pump after a delay of 5s following pump switch on. This
ensures that the machine does not attempt to pump against a
squeeze valve that is still closed.

546 MX07_146_0905EN
 Operation

MX07_146_0905EN 8

Open squeeze valve

" Switch the pump on at the remote control.

å The squeeze valve opens, the concrete can flow through
the squeeze valve and the end hose.

MX07_146_0905EN 9

Closed squeeze valve

" Switch the pump off at the remote control.

å The squeeze valve closes and interrupts the flow of
concrete.

MX07_146_0905EN 547
 Operation

5.7 Climbing Once the placing site has reached a height at which the placing
boom can no longer easily be used, it is necessary to shift the
tubular column upwards. This process of shifting upwards is
knownas climbing.

5.7.1 Preconditions The preconditions listed below must be fulfilled and you must
complete some preparations before you can begin climbing.

Danger
The following points are preconditions for climbing. If these are not
observed, the boom may tip over or other damage may be caused.
 The folded boom must be in the climbing position.
 The tubular column must stand vertical.
 The tubular column must be fixed in two floors by the corner
brackets.
 Below the last fixing point, the length of the tubular column must
be at least as long as the intended climbing height.
 No ladder elements or ladder hooks should be located on the
tubular column underneath floors.
 The delivery line must be disconnected beneath the tubular
column.
 The tubular column must be released from the cruciform base.
 The floors must be able to hold the load of the stationary boom.
 There must be sufficient space around the holes in the floor to
enable you to pull the horizontal bolts out of the climbing column
as far as the stop.

Note
Fitting the corner brackets is described in the chapter
Transport,
assembly and connection".

548 MX07_189_1003EN
 Operation

Floor load during the climbing procedure

1
MX07_189_1003EN 1

No. 1 Designation
1 Pivoting pawl

The pivoting pawl on the climbing system is folded out during the
climbing procedure, and carries the weight of the stationary boom.
Ensure that the floor levels can bear the floor load. The floor load
must not exceed 365 kN.

Note
The floor load can vary depending on the configuration of the
stationary boom. Contact Putzmeister to obtain the documentation
that applies to your configuration.

MX07_189_1003EN 549
 Operation

Sheeting supports to absorb bearing pressure during climbing

MX07_189_1003EN 2

No. 1 Designation
1 Sheeting support

Bearing pressure can be absorbed and transferred onto several

levels through the use of sheeting supports.

550 MX07_189_1003EN
 Operation

Space requirement around the holes in the floor

0.3m

2
3

1.0m 3

0.3m

0.3m 1.0m 0.3m

MX07_189_1003EN 3

No. 1 Designation
1 Hole in floor
2 Climbing column
3 Horizontal bolt
4 Corner bracket

There must be a gap of at least 0.3m around the holes in the floor so
that you can pull out the horizontal bolts to the stop on both sides of
the climbing column.

MX07_189_1003EN 551
 Operation

5.7.2 Limit parameters

Caution
The maximum overall length of the tubular columns specified here
must not be exceeded, as there is otherwise a risk of overloading the
stationary boom.
If you wish to use the placing boom in other conditions, you must
request the relevant documents from Putzmeister.

Stationary boom, clamped in position

D MX07_190_0710EN 1

No. Length of the tubular column ... Height of job > 20.5 m
A for clamped stationary boom, max. 19.5 m
B above the uppermost fixing point, max. 15.5 m
C between two fixing points, min. 3m
D below the last fixing point 1m
Boom rest position and climbing position vertical

552 MX07_190_0710EN
 Operation

5.7.3 Before initial climbing Before you can start to climb, you must
− connect the climbing system hydraulic lines to the hydraulic
powerpack
− connect the climbing system remote control
− bleed the climbing cylinder
− remove the wedges located between the corner brackets and
thetubular column.

Climbing hydraulic
system

MX07_191_0807EN 1

Connecting the hydraulic lines

" Connect the climbing system hydraulic lines to the hydraulic

power pack.

MX07_191_0807EN 553
 Operation

Connecting the hydraulic lines

Note
Make sure that the hydraulic lines can move freely underneath the
tubular column so that they can be drawn upwards at the same time
when the climbing unit is moved.

MX07_191_0807EN 2

Climbing system hydraulic lines

" Connect the climbing system hydraulic lines to the hydraulic

line of the climbing column.

554 MX07_191_0807EN
 Operation

Connecting the Only connect the climbing system remote control once you are ready
climbing system to climb. You must disconnect the climbing system remote control
remote control and store it in a secure place as soon as the climbing operation is
complete.

MX07_191_0807EN 3

Switching off the main switch

" Switch the main switch on the control cabinet to off.

MX07_191_0807EN 4

Connecting the climbing system remote control to the control cabinet

" Plug the climbing system remote control connector into the
connector socket on the control cabinet and secure it.

" Guide the remote control with its cable along the tubular
column down to the climbing system.

MX07_191_0807EN 555
 Operation

Note
You must switch the main switch on the control cabinet to on and
activate the climbing function on the boom remote control to operate
the climbing cylinders.

MX07_191_0807EN 5

Switching on the main switch

" Switch the main switch on the control cabinet to on.

" Switch the electric motor on.

MX07_191_0807EN 6

Climbing function toggle switch

" Activate the climbing function on the boom remote control.

" Switch the climbing system remote control on using the

keyswitch.

556 MX07_191_0807EN
 Operation

Bleeding the climbing After connecting the climbing system hydraulic lines to the hydraulic
cylinders lines of the climbing column, it is necessary to bleed the climbing
cylinder.

" In order to bleed the climbing cylinder, extend and retract it

slowly 2 or 3 times as far as the stop.

MX07_191_0807EN 557
 Operation

5.7.4 Moving the climbing Before commencing the climbing procedure, you must move the
unit to a floor climbing unit (consisting of the upper climbing carriage, hydraulic
cylinder and lower climbing carriage) to a floor.

MX07_199_0808EN 1

No. 1 Designation
1 Horizontal bolt

Note
During the time when the tubular column is standing on the floor, the
horizontal bolt is not yet withdrawn.
Once the tubular column is clamped in position, the horizontal bolt
iswithdrawn − as shown above − and supports the weight of the
stationary boom.
The following operations have been described in order to show an
example of the tubular column clamped in position, as a starting
position. The climbing unit is moved for the first time to a floor in
asimilar way.

558 MX07_199_0808EN
 Operation

3
5

MX07_199_0808EN 2

Climbing unit

No. 1 Designation
1 Chain hoist
2 Upper climbing carriage
3 Climbing cylinder
4 Lower climbing carriage
5 Climbing unit (2, 3, 4)

MX07_199_0808EN 559
 Operation

MX07_199_0808EN 3

" Attach the upper climbing carriage (2) to the hook of the chain
hoist (1).

560 MX07_199_0808EN
 Operation

Releasing the
climbing carriage

MX07_199_0808EN 4

The detent pawls of the upper and lower climbing carriage may be
locked during concreting, where required.

" Release the detent pawl interlocks of the upper and lower
climbing carriage.

MX07_199_0808EN 561
 Operation

MX07_199_0808EN 5

Swivelling in the pivoting pawl

" Pull the climbing unit upwards using the chain hoist.

" Swivel in the pivoting pawl (1).

" Using the chain hoist, pull the climbing unit over the next floor.

562 MX07_199_0808EN
 Operation

Arresting the lower

climbing carriage

MX07_199_0808EN 6

Swivelling out the pivoting pawl

" Swivel out the pivoting pawl (1) as soon as it is positioned

above the next floor.

MX07_199_0808EN 563
 Operation

MX07_199_0808EN 7

Arresting the lower climbing carriage

" Place the support bracket (1) under the pivoting pawl.

" Lower the climbing unit until the pivoting pawl rests against
thesupport bracket.

" Press the interlock (2) of the lower climbing carriage

å The lower climbing carriage is arrested.

564 MX07_199_0808EN
 Operation

Removing the wedges Before commencing the climbing procedure, you must remove the
wedges fastening the tubular column in the holes in the floor to the
corner brackets.

MX07_200_0808EN 1

Removing the wedges

" Use the climbing cylinder to briefly raise the tubular column in
order to release the wedges.

" Pull out the 8 wedges (1) between the tubular column and the
corner brackets on each floor.

MX07_200_0808EN 565
 Operation

5.7.5 Climbing procedure The climbing cylinder is positioned on the floor and uses the upper
climbing carriage to push up the climbing rail, which is attached to
the tubular column.

1. 2. 3. 4. 5.

MX07_201_0808EN 1

No. 1 Designation
1 Climbing rail
2 Upper climbing carriage
3 Upper climbing carriage detent pawl
4 Climbing cylinder
5 Lower climbing carriage
6 Lower climbing carriage detent pawl

566 MX07_201_0808EN
 Operation

A climbing procedure consists of several climbing operations. In

thestart position, the detent pawl of the upper climbing carriage
isengaged in the climbing rail.

" If the detent pawl is not engaged in the climbing rail, retract the
climbing cylinder.
å Before the end of the cylinder’s return travel, the detent
pawl of the upper climbing carriage engages in the climbing
rail.
å The new start position (5.) has now been reached.

" Extend the climbing cylinder (1.).

å As the climbing cylinder lifts, the tubular column is raised.
å Before the end of the lift, the detent pawl of the lower climb

ing carriage engages in the climbing rail and holds the tubular
column in position (2.).

" Retract the climbing cylinder (3.).

å Before the end of the cylinder’s return travel, the detent
pawl of the upper climbing carriage engages in the climbing
rail (4).
å The new start position (5.) has now been reached.

MX07_201_0808EN 567
 Operation

Inserting the If the tubular column is supported on a floor by the horizontal bolt,
horizontal bolt the horizontal bolt must be inserted into the climbing column before
commencing the climbing procedure to the next floor.

MX07_202_0808EN 1

" After the first climbing operation, insert the horizontal bolt (1)
into the climbing column.

You can now commence the climbing procedure.

Repeating the Keep repeating the climbing operation until you have raised the
climbing operation tubular column to the required height.

Danger
If the remaining length of tubular column below the lowest floor is
insufficient, you must fit the next 4 corner brackets on the third floor
level and move the climbing unit to the next floor up. You must never
lift the tubular column out of one floor level if the tubular column is
not held in at least two other floor levels by corner brackets.

568 MX07_202_0808EN
 Operation

5.7.6 Terminating the You must terminate the climbing procedure if you have raised the
climbing procedure horizontal bolt of the climbing column above the lower floor.

" Retract the climbing cylinder.

å Before the end of the cylinder’s return travel, the detent
pawl of the upper climbing carriage engages in the climbing
rail.

Arresting the upper

climbing carriage

MX07_203_0808EN 1

Arresting the upper climbing carriage

" Press the interlock (1) of the upper climbing carriage.

å The upper climbing carriage is arrested.

MX07_203_0808EN 569
 Operation

Withdrawing the
horizontal bolt

2 MX07_203_0808EN 2

" Pull the horizontal bolt (1) out of the climbing column and back
to the stop on both sides.

" Place a support plate (2) under each horizontal bolt.

" Briefly raise the tubular column until the detent pin of the lower
climbing carriage disconnects from the climbing rail.

Note
When lowering the tubular column, make sure that the detent pawl of
the lower climbing carriage does not engage in the climbing rail,
otherwise you will not be able to lower the tubular column any further.

" Lower the tubular column until the horizontal bolt rests against
the support plate.

570 MX07_203_0808EN
 Operation

Placing the wedges

MX07_204_0808EN 1

Only use wedges in the upper and lower levels

" Drive 8 wedges (1) between the tubular column and the corner
brackets in the upper level.

" Drive 8 wedges (1) between the tubular column and the corner
brackets in the lower level.

Caution
During concreting operations and when the boom is in the rest posi
tion, the tubular column must only be fastened to the corner brackets
by wedges in two levels.
If you are using corner brackets in three levels, the tubular column
must only be wedged to the corner brackets in the upper and lower
level, otherwise the horizontal loads which are transferred to the
structure at the middle level will be excessive.

MX07_204_0808EN 571
 Operation

Fastening the After climbing you will have to extend the delivery line and fasten it,
delivery line depending on the type of climbing frame and guides provided for
the delivery line. Below we show an example of the floor frame:

3.

2.

1.

MX07_205_0808EN 1

Extending and fastening the delivery line

" Fasten one clamp at each hole in the floor(1.) using nailable
fixing plugs (10−12mm diameter).

" Extend and connect the delivery line (2.).

" Fasten the delivery line to the clamps using pipe brackets (3.).

572 MX07_205_0808EN
 Operation

5.8 Satellite use If you own a number of tubular columns and quick mounting
adapters for the tubular columns, you can quickly move the boom
pedestal from one tubular column to another. This is known as
satellite use".

5.8.1 Different types The principle of satellite use is not dependent on the type of boom.
of boom Satellite use for an MXR32 is described below. This is a boom with
ballast and without a coupling joint in the arm assembly. The oper

ations for other arm assemblies are the same.

Caution
For booms with a coupling joint in the arm assembly, you should also
refer to the sections in these Operating Instructions entitled
Fitting
the arm assembly with quick disconnect point" and
Disassembly".

When working at height, use the climbing aids and working plat

forms provided for reasons of safety or wear a safety harness. The
relevant national regulations must be complied with.

MX07_102_0808EN 573
 Operation

5.8.2 Removing the

arm assembly

1.

22604300

Arm assembly in central position

" Slew the folded arm assembly to the centre of the slewing
circle (1.).

" Separate the delivery line at the boom pedestal.

" Undo the hydraulic connections on the boom pedestal.

574 MX07_102_0808EN
 Operation

22601708

Removing the boom

" Hook the crane hook into the lifting eye on the arm assembly.

Danger
Before removing the pins which connect the boom pedestal to the
tubular column, the weight of the boom pedestal must be supported
by crane.

Note
Excessive tension on the crane cable will make it impossible to
remove the pins.

MX07_102_0808EN 575
 Operation

MX07_102_0808EN 2

Disassembling the tubular column

" Release and remove the four pins (1).

576 MX07_102_0808EN
 Operation

5.8.3 Moving the arm assembly

MX07_102_0808EN 3

Moving the boom pedestal

" Transport the boom pedestal to the other tubular column.

MX07_102_0808EN 577
 Operation

5.8.4 Fitting the arm assembly

MX07_102_0808EN 4

Fitting the boom pedestal

" Carefully locate the boom pedestal on the tubular column.

578 MX07_102_0808EN
 Operation

MX07_102_0808EN 5

Connecting the boom pedestal to the tubular column

" Connect the boom pedestal to the tubular column using the
four pins (1).

1 2
MX07_102_0808EN 6

Securing the pins

" Secure the four pins (1) using the locking plate (2).

" Connect the hydraulic lines and delivery pipes, as described

on page 435.

MX07_102_0808EN 579
 Operation

5.9 Cleaning This section describes the operations for cleaning the boom delivery
line after each job. It is best if you clean the delivery line at the same
time as you clean the delivery line on the concrete pump. Please
note the following for all other cleaning jobs:

Note
Only use cold water at a maximum water pressure of 5 bar for cleaning
all painted surfaces in the first four weeks of using the machine. Do not
use any aggressive cleaning agents. The paint is not fully cured until
after this period and you will then be able to use steam cleaning devices
or other equipment.

Never use sea water or other water containing salt for cleaning pur
poses. You must rinse off any sea water that gets on the machine.

Lock the remote control units away during cleaning operations. The
remote control units do not have a watertight casing. Execute the
machine functions necessary for the cleaning operations from the
machine itself.

Danger of explosion
You clean the delivery line with compressed air at your own risk.
Putzmeister accepts no liability for damage caused by cleaning with
compressed air.

580 MX07_009_9408EN
 Operation

5.9.1 Suction cleaning

12500100

Inserting a water−soaked wash−out sponge

A clean delivery line is the best prerequisite for being able to begin
delivering concrete immediately at the next job without the need for
great preparations. Suction cleaning is the simplest and least haz

ardous method of cleaning and is described below.

" Switch the concrete pump off.

" Insert a water−soaked wash−out sponge (cube) into the end

hose outlet.

" Shift the placing boom into a uniformly rising position.

" Switch pump over to reverse pumping and suck the wash−out
sponge back through the delivery line.

Note
Follow the cleaning instructions provided by the manufacturer of the
concrete pump for the further procedure.

" Repeat the cleaning procedure, as a single suction pass is not

sufficient.

MX07_009_9408EN 581
 Operation

5.9.2 Tapping
the delivery line

11000101

Tapping the delivery line with a hammer handle

" Occasionally tap the delivery line with a piece of hard wood
(hammer handle) during reverse suction to determine the loca

tion of the wash−out sponge.

Note
Use only a hammer handle to tap on the delivery line, as otherwise
the pipe may be damaged.

" Clean all seals and the seal seats. Grease the seal before
refitting it.

" Then clean the remaining parts of the machine and spray the
metallic parts with an anti−corrosion agent or an adhesion
inhibitor.

Danger of explosion
Atomized preservation agents are highly explosive. Keep away from
all sources of ignition whilst spraying.

Danger of poisoning
Cleaning agents, solvents or preservation agents sprayed in air can
enter the lungs and trigger serious health problems. You should,
therefore, always wear respiratory protection during this work.

582 MX07_009_9408EN
 Operation

5.9.3 Pressurized water A clean delivery line is the best prerequisite for being able to begin
cleaning delivering concrete immediately at the next job without the need for
great preparations. Cleaning with pressurized water, which is more
thorough than suction cleaning, but requires more effort, is described
below.

" Switch the pump over to reverse pumping" and relieve the pres

sure on the delivery line by 1 or 2 strokes of reverse pumping.

" Switch the pump off.

" Shift the boom to a largely horizontal position to prevent the

concrete running back.

11000502

Pressurized water cleaning

" Push two or three water−soaked wash−out sponges into the

cleaning aperture of the concrete pump and close it.

" Fill the agitator hopper with water.

" Switch the pump over to forward pumping".

" Eject the concrete from the delivery line forwards. If one
hopper−full is not sufficient on larger placing booms, you will
have to refill the hopper with water before air is taken in. Con

tinue pumping until the wash−out sponges exit from the end
hose. Take care to ensure that the water flowing behind it does
not run into the formwork.

MX07_009_9408EN 583
 Operation

" Then switch the pump over to reverse pumping and place the
placing boom in the vertical position so that the cleaning water
can drain out of the delivery line.

Caution
The delivery line must be completely drained if there is a risk of frost.

" Clean all seals and the seal seats. Grease the seal before
refitting it.

" Then clean the remaining parts of the machine and spray the
metallic parts with an anti−corrosion agent or an adhesion
inhibitor.

Danger of explosion
Atomized preservation agents are highly explosive. Keep away from
all sources of ignition whilst spraying.

Danger of poisoning
Cleaning agents, solvents or preservation agents sprayed in air can
enter the lungs and trigger serious health problems. You should,
therefore, always wear respiratory protection during this work.

584 MX07_009_9408EN
 Operation

5.10 Folding the 4 Z boom Also read the Unfolding the 4Zboom" section.

Note
When the arm assembly is folding, the end hose cannot automati
cally drop into the end hose catch brackets because of the design
ofthe arm assembly. Therefore, you must first move the arm into a
position which allows the end hose to drop into the end hose catch
brackets.

Caution
Always observe the specified sequence for extending and folding
the boom. Failure to comply with the sequence may allow the crank
lever in the Chinge to compress the delivery line, adjacent hydraulic
cylinders or other components.

Carefully fold the placing boom.

MX07_114_0207EN 585
 Operation

5.10.1 Folding sequence

Danger

MX07_114_0207EN 1

Arms3 and4 must not be moved behind the C hinge when unfolded
or partially unfolded during the entire boom operation. In this arm
position, the rod side C cylinder hydraulic pressure is so high that
the pressure limiting valve responds and the boom will gradually
slump.

There is also a risk of uncontrolled boom movements.

Before moving arm3 to the rear, you must move arm4 towards
arm3 until the boom tip is approximately 1m from the C hinge.

586 MX07_114_0207EN
 Operation

Catching the
end hose

MX07_114_0207EN 2

" First retract arm3 until it is vertical.

MX07_114_0207EN 3

" Then unfold arm4 in a single motion until the end hose drops
into the end hose catch brackets.

MX07_114_0207EN 587
 Operation

Caution
You must fold arm3 in fully before you fold arm4 in fully, otherwise
the Chinge crank lever will press on the boom tip pipe bend.

Therefore, only fold arm4 in fully once you have folded arm3 in fully.

Arm 4

MX07_114_0207EN 4

" Fold arm4 in so that the boom tip is approximately 1m from
the Chinge.

588 MX07_114_0207EN
 Operation

Arm 3

MX07_114_0207EN 5

" Fold arm3 in fully until it rests against arm2.

Arm 4

MX07_114_0207EN 6

" Fold arm4 in fully until it rests against arm3.

MX07_114_0207EN 589
 Operation

Caution
Take care when folding arm2 that you do not damage the working
platform or other elements. It may be necessary to raise arm1
higher.

Arm 2 and arm 1

MX07_114_0207EN 7

" Fold arm2 in fully until it rests against arm1.

" Raise arm1 until the rest position is reached.

590 MX07_114_0207EN
 Operation

5.10.2 Rest position The boom is vertical in the rest position.

MX07_114_0207EN 8

MX07_114_0207EN 591
 6 Maintenance

In this chapter you will find information on maintenance work which is

necessary for the safe and efficient operation of the machine.

Following the general maintenance information, you will find the

maintenance cards necessary for this machine. The table of contents
includes a summary of the maintenance cards in numerical order,
you will find an alphabetical summary in the Index of key words
under the entry for Maintenance cards".

We should like here to emphasise expressly that all prescribed

checks, inspections and preventative maintenance work must be
conscientiously carried out. Otherwise, we will refuse to accept any
liability or to honour the warranty. Should you ever be in any doubt,
our After Sales Department is always ready to give you advice and
assistance.

BP09_001_9405EN
 Maintenance

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

Note
Have the initial After Sales service after 100 hours of operation
carried out by a Putzmeister After Sales service engineer. The
machine operator responsible for the machine should be present
forthis service.

every ... hours of operation

Assembly Action other intervals
daily 250 500 1000 1500 2000

Lubricate all lubrication points D weekly

Visual and function check on all

D
safety equipment

Check threaded unions against

as required
General torque table

annually;
Inspection by subject expert D before a new
installation

Visual inspection of electrical cabling D

Check hydraulic fluid level D

Drain off condensate water D

Visual check of the lines (damage/

D
leaks)

Hydraulic system Full fluid change (after fluid analysis) D

Clean fluid sump D

Check hydraulic cylinder for tight

monthly
ness (visual inspection)

Clean hydraulic fluid radiator D D

MX09_001_0402EN 61
 Maintenance

every ... hours of operation

Assembly Action other intervals
daily 250 500 1000 1500 2000
Check contamination indicator on
D
thefilters
Fluid filter Replace boom filter element as required

Replace vacuum filter element as required

Boom Tighten castle nuts on bolt bearings biannually

Coupling safety clips D as required

Delivery line
Check wall thickness D as required

62 MX09_001_0402EN
 Maintenance

6.2 General tightening Tightening torques depend on bolt grade, thread friction and bolt
torques head bearing area. The values given in the following tables are for
guidance. These values should only be used if no other values are
specified in the relevant chapters of the Operating Instructions or in
spare parts sheets.

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

BP09_003_0607EN 63
 Maintenance

6.2.1 Set screws and nuts The following tables contain the maximum tightening torques MA inNm
for set screws of strength class8.8 and nuts of strength class8, with
a coefficient of friction of µtot=0.14, threads lightly oiled or lightly
greased.

Note
All tightening torques are multiplied by a factor of 1.1 for bolts with
adhesive in the locking threads (MK).

MA [Nm] MA [Nm]

µtot0.14 x1.1 (MK) µtot0.14 x1.1 (MK)

M4 3.1 3.4 M 20 430 473

M5 6.1 6.7 M20x1.5 480 528
M6 10.4 11.4 M 22 580 638
M7 17 19 M22x1.5 640 704
M8 25 28 M 24 740 814
M8x1 27 30 M24x1.5 830 913
M9x1 40 44 M24x2 810 891
M 10 51 56 M 27 1100 1210
M10x1 57 63 M27x1.5 1200 1320
M10x1.25 54 59 M27x2 1190 1309
M 12 87 96 M 30 1500 1650
M12x1.25 96 106 M30x1.5 1670 1837
M12x1.5 92 101 M30x2 1610 1771
M 14 140 154 M 33 2000 2200
M14x1.5 150 165 M33x2 2250 2475
M 16 215 237 M 36 2600 2860
M16x1.5 230 253 M36x2 2950 3245
M 18 300 330 M 39 3400 3740
M18x1.5 350 385 M39x2 3720 4092
M18x2 330 363

64 BP09_003_0607EN
 Maintenance

6.2.2 Flared screwed joint, After each time the joint is undone, the union nut must be tightened
reassembly again securely without excessive force.

Flared screwed joints

RAD* / Type MA [Nm] RAD* / Type MA [Nm]
6 L 20 18 L 120
8 L 40 20 S 250
L 55 25 S 400
12
S 80 30 S 500
15 L 70 38 S 800
16 S 130
* RAD = pipe external diameter

Note
Hold threaded connection fast against turning with wrench.

10400100

Tightening flared screwed joint

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

BP09_003_0607EN 65
 Maintenance

6.3 Functional fluids This section lists all the functional fluids used in your machine.

Caution
Never use hydraulic fluids or lubricants with additives such as
molybdenum. Such additives can attack the bearings.

6.3.1 Hydraulic fluid The hydraulic system is filled with:

− mineral hydraulic fluid (HLP) or
− biologically degradable hydraulic fluid based on a synthetic ester
(HEES) or
− non−readily flammable hydraulic fluid (HFC).

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

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

66 BP09_004_0502EN
 Maintenance

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

When hydraulic fluids of different viscosity grades are mixed, the

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

When the hydraulic fluid is changed, some 10−15% of the old hy
draulic fluid remains in the system (in cylinders, pumps, lines, etc).

Take note of VDMA’s changeover guidelines and manufacturer’s

instructions if you are changing over your fluid. Please contact the
manufacturers concerned if you have any queries regarding the
suitability and miscibility of hydraulic fluids.

BP09_004_0502EN 67
 Maintenance

6.3.2 Level of contaminant Level of contaminant 19/16/12 in accordance with ISO4406 is speci

fied for lubrication and the hydraulic system. You can find the level of
contaminant of the initial filling from the test report on the machine
card.

6.3.3 Lubricant analysis We can carry out a lubricant analysis for you should you discover
that the functioning of your machine is impaired with one of the
lubricants or hydraulic fluids used. Please consult Putzmeister,
Department APS (After Sales) and request our analysis kit
(materialno. 257260.004). We will carry out a lubricant analysis
todetermine the cause.

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

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

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

Observe the national and regional regulations applicable to your

area. Only work with waste disposal companies who are approved
by the responsible authorities.

68 BP09_004_0502EN
 Maintenance

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

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

Please use only Putzmeister hydraulic fluid, material no. 239693000,

when you are topping up the hydraulic fluid or carrying out a full fluid
change if your machine was filled with a synthetic ester in the works.

Putzmeister accepts no liability for damages caused by mixing fluids

from different manufacturers.

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

The proportion of residual fluid must not be greater than 2% after a

fluid change from HLP to HEES. This means that a flushing filling with
the full quantity of the new hydraulic fluid must be carried out. In
addition, for reasons of gasket compatibility, a fluid change must
becarried out no later than 6months after the machine is commis
sioned. It should also be noted, at this point, that all filters must
bechanged after 50 hours of operation, since deposits may be
dissolved and transported to the filters by the new fluid.

BP09_016_0708EN 69
 Maintenance

Caution
The following points must be complied with in order to prevent
damage:
 You must warm the machine up briefly if you wish to start using it
when the hydraulic fluid temperature is below 0_C. To do this,
engage the power take−off, switch off the concrete pump and
allow the machine to idle for a few minutes.
 The machine should not be placed under full load until the tem
perature of the hydraulic fluid (VG46) has risen above 10_C.
 The ideal temperature for the hydraulic fluid (HLP or HEES, VG46)
is between 40_C and 70_C.

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

610 BP09_016_0708EN
 Maintenance

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

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

BP09_016_0708EN 611
 Maintenance

6.4.2 Greases
Greasing Centralized Greasing the pump
(manual) lubrication system tube in rotor pumps
Marking in
accordance K2K−30 K1K−30 
with DIN 51 502
Requirements
DIN 51 825 DIN 51 825 
standard
Characteristics mineral, lithium soap 
Viscosity grade, NLGI Class 2 NLGI Class 1

NLGI Class DIN 51818 DIN 51818
Material no. 360000.009 360001.008 290207.008

Note
We recommend the following grease, rather than those specified in
the lubricant table, should you wish to fill the centralized lubrication
system with a low temperature grease in extremely cold conditions:
Marking in accordance with DIN51502: KE2G−60, NLGI Class2

612 BP09_016_0708EN
 6.4.3 Hydraulic fluids
BP09_017_0708EN

Category Mineral oil Synthetic ester Aqueous solutions

Type HLP HEES HFC
Classification
DIN 51502
ISO 6743/0
Requirement
DIN 51524 Part 2  
ISO 6743 Part 4  
VDMA 24318 24568 24317/24320
Others   7th Luxembourg Report
Viscosities
DIN 51519
ISO 3448
2
mm /s ISO VG 32 46 68 46 46
Use
15_C to +80_C
10_C to +90_C 0_C to +95_C
10_C to +90_C
20_C to +60_C
Particular char

 biodegrades quickly non−readily flammable
acteristics
Initial filling
Material no. 490984 000171.007 279845.009 239693.000 239879.002
BECHEM HYDROSTAR FUCHS HYDROTHERM
Manufacturer 

Maintenance
HEP46 46M
Changeover guidelines
VDMA  24569 24314
613
 Maintenance cards

In this section you will find the maintenance cards necessary for this
machine. The table of contents includes a summary of the mainten

ance cards in numerical order, you will find an alphabetical summary
in the Index of key words under the entry for Maintenance cards".

BP09_013_0209EN 615
616
 Maintenancecard
00−001
Page 1 of 2

00–001 Visual checks This maintenance card describes visual checks that you must
carryout before commencing any maintenance work. You will find
the service intervals in the maintenance summary at the start of this
chapter.

See also the maintenance cards:

Filter change
Hoses

No special tools required.

Danger
Inspect the electrical cables particularly closely and carefully. There
is a danger of overvoltages from defective cables, particularly when
there is high air or ambient humidity. There is a danger of fire and
explosion through the formation of sparks when the machine is used
in a potentially explosive atmosphere.

WK00_001_9411EN 617
 Maintenancecard
00−001
Page 2 of 2

General The general visual inspections listed below should always be carried
out before any maintenance work, and also each time before starting
work with the machine.

" Check the fill levels of the functional fluids.

" Check that all safety equipment is available and in a fully func

tioning condition.

Electrical system You must have any damage found in the electrical system rectified
immediately by a qualified electrician.

" Check that all electrical connections are secure and free from
corrosion.

" Check that the electrical cables have no breaks.

" Check the insulation on the electrical cables.

Hydraulic system Timely detection and rectification of damage to the hydraulic system
can prevent lengthy downtimes and high repair costs.

" Check that the displays on the vacuum meter of the suction
filters are still in the green range. The vacuum filters must be
replaced if the displays are in the red range.
Maintenance card: Filter change

" Check the contamination indicators on the boom filters. The

filters are in order if the red button remains depressed. The
filter must be replaced if the red button pops out.
Maintenance card: Filter change

" Check the oil cooler for contamination and deposits.

" Check all hydraulic hoses for leaks.

Maintenance card: Hoses

" Check all hydraulic threaded unions for tightness and leaks.
Maintenance card: Hoses

618 WK00_001_9411EN
 Maintenancecard
03−001
Page 1 of 6

03–001 Changing the This maintenance card describes how to carry out a full oil change
hydraulic fluid on the hydraulic system. You will find the service intervals in the
maintenance summary at the start of this section.

See also the maintenance cards:

Function checks
Filter change
Hoses

No special tools required.

Note
Cleanliness is of the greatest possible importance in the mainten
ance of hydraulic systems. You must make it impossible for dirt or
other impurities to enter the system. Even small particles may cause
valves to be scored, pumps to seize and choke and control bores to
become blocked.

Hydraulic fluid drums must stand for some time before the fluid is
taken from them. Never roll the barrels to where you will be drawing
off the fluid. Clean bungs, filler caps and their surroundings before
opening them.

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

WK03_001_9411EN 619
 Maintenancecard
03−001
Page 2 of 6

Preparation The following tasks must be carried out before starting the full fluid
change:

" Switch off the remote control.

" Switch the hydraulic pumps off.

" Reduce fluid pressure completely.

" Check the contamination indicator on the vent filter of the fluid
reservoir. You must replace the filter element for the vent filter
when the red check ring is visible in the inspection glass.
Maintenance card: Filter change

10401903

1 Red check ring in the inspection glass

620 WK03_001_9411EN
 Maintenancecard
03−001
Page 3 of 6

Danger
The accumulator pressure in pressurized systems must be released.

" Switch the drive engine off.

" Secure the system against unauthorized starting  if you have

any keyed switches, remove the key and disconnect the sup

ply voltage.

" Secure your working area and fix notices to the blocked con

trols and setting devices.

Changing the fluid

10300400

Draining off the fluid

Environmental protection
You must make sure you collect the old hydraulic fluid and dispose
of it in accordance with the regulations. Biologically degradable hy
draulic fluids must also be disposed of separately from other waste,
just like mineral hydraulic fluids!

" Remove a hose from the hydraulic system tank and drain off
the fluid.

WK03_001_9411EN 621
 Maintenancecard
03−001
Page 4 of 6

" Then disconnect all hoses from the tank.

Note
Mark the hoses and their connection points for re−assembly.

10400300

Marking the hoses

" Wipe out all the openings with a lint−free cloth. Wipe as far into
the tank as possible when doing this. You should also re

member that there may also be separate apertures intended
for tank cleaning.

" Remove all filter inserts.

Maintenance card: Filter change

" Change all filters and refit the filter elements.

" Replace any defective hoses.

Maintenance card: Hoses

Environmental protection
Dispose of the old filter inserts in accordance with the regulations in
force.

622 WK03_001_9411EN
 Maintenancecard
03−001
Page 5 of 6

10300500

Filling the tank

" Fill the tank with new fluid.

Note
Only fill the tank through the mesh in the filler inlet. Fill up the tank up
to the
Maximum" marking after bleeding and a test run. Use only the
hydraulic fluids specified in the lubrication recommendations.

" Remove the dirt deposits from the oil cooler.

" Check all screwed joints and tighten where necessary. Check
all flared screwed joints.
Maintenance card: Hoses

" Check the electrical connections.

" Carry out all function checks.

Maintenance card: Function checks

" Bleed hydraulic system.

" Carry out several test runs.

" Refit all the safety equipment, markings and notices you have
removed.

WK03_001_9411EN 623
 Maintenancecard
03−001
Page 6 of 6

624 WK03_001_9411EN
 Maintenancecard
03−002
Page 1 of 2

03–002 Function checks This maintenance card describes the inspection of machine func

tions. The inspections are carried out with the machine running. You
will find the service intervals in the maintenance summary at the start
of this chapter.

No further maintenance cards required.

The following special tools are required:

Pressure gauge and connections for the tapping points shown in the
hydraulic circuit diagram

Note
Only qualified personnel authorized by us may carry out work on the
hydraulic system. Notify the Putzmeister After Sales department or
the dealer/agent who looks after you immediately should you find
any irregularities.

" Measure the pressures generated by the pumps, using the

measuring equipment specified directly on the pumps, and
compare your results with the values specified in the test
reading.

" Check the proper functioning of the pressure−relief valves in

the high pressure circuit and the pressure accumulator.

WK03_002_9411EN 625
 Maintenancecard
03−002
Page 2 of 2

626 WK03_002_9411EN
 Maintenancecard
04−012
Page 1 of 6

04–012 Changing the suction filter This maintenance card describes how to change the suction filter
element element. You will find the maintenance intervals in the maintenance
summary at the start of this chapter.

No further maintenance cards required.

No special tools required.

Note
Replace the filter element once the indicator on the vacuum meter is
in the red zone.

Cleanliness is of the utmost importance in the maintenance of hy

draulic systems. Prevent any type of dirt from entering the system.
Even small particles of dirt may cause valves to be scored, pumps
toseize and throttle and control bores to become blocked.

Hydraulic fluid barrels must stand for some time before the fluid is
removed from them. Never roll the barrels to where you will be draw
ing off the fluid. Clean bungs and filler lids as well as the area around
them before opening.

If possible, you should use a charging set to fill up the hydraulic

system. Never leave the reservoir lid open longer than necessary.

WK04_012_0308EN 627
 Maintenancecard
04−012
Page 2 of 6

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
Dispose of used filter elements in accordance with the relevant
regulations.

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

" Switch off the hydraulic pumps.

" Switch off the engine/motor.

" Dump the fluid pressure completely.

" Switch off the remote control.

Danger
The pressure accumulated in pressurized systems must be dumped.

" Secure the machine against being started by unauthorised

persons  if you have any key−operated switches, remove the
key and disconnect the supply voltage.

" Secure your work area and fix notices to the locked controls
and setting devices.

628 WK04_012_0308EN
 Maintenancecard
04−012
Page 3 of 6

Changing

1. 3

2.
4.
3.

WK04_012_0308EN 1

No. 0 Designation
1 Lid
2 Hexagon nut
3 Plug
4 Drain cock

WK04_012_0308EN 629
 Maintenancecard
04−012
Page 4 of 6

" Place a container under the drain cock (4) to allow you to catch
the escaping hydraulic fluid.

" Unscrew the hexagon nuts (2) as far as the stop and remove
the filter element without turning it to the stop [1.].
å A shut−off valve automatically interrupts the hydraulic fluid
supply.

" Open the upper plug (3) to provide an air supply [2.].

" Open the drain cock (4) and allow the hydraulic fluid to run out
of the filter housing [3.].

" Turn the lid (1) anti−clockwise and remove the filter element
completely [4.].

630 WK04_012_0308EN
 Maintenancecard
04−012
Page 5 of 6

WK04_012_0308EN 2

No. 0 Designation
1 Hexagon nut
2 Filter element
3 Magnetic rod

" Unscrew the hexagon nut (1) from the magnetic rod (3).

" Turn the filter element (2) to the left and withdraw it from the
magnetic rod (3).

" Wipe the magnetic rod (3) lengthways with a clean rag.

Note
Before fitting new filter elements, you must check all O−rings and
other seals on the filter elements and replace them if damaged.

" Fit a new filter element and screw the hexagon nut (1) back on.

Environmental protection
Any hydraulic fluid which escapes must be disposed of in accord
ance with the relevant regulations.

WK04_012_0308EN 631
 Maintenancecard
04−012
Page 6 of 6

Correction dimension The filter element must be adjusted to the correct length so that the
filter element opens to the rear after the filter housing has been fitted.
Use the length (correction dimension) given on the spare parts
sheet. If no correction dimension is specified, the length of the filter
element is as designed.

Note
The correction dimension is measured from the lower edge of the lid
to the tip of the filter element.

10400401

K=Correction dimension

" Check and, if necessary, adjust the filter element to the correc

tion dimension.

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

" Clean the filter housing thoroughly with a clean rag.

" Install a new filter element. The installation procedure is the

reverse of the procedure for removing a filter element.

632 WK04_012_0308EN
 Maintenancecard
04−013
Page 1 of 6

04–013 Changing the pressure filter This maintenance card describes how to change the pressure filter
element element. You will find the maintenance intervals in the maintenance
summary at the start of this chapter.

No further maintenance cards required.

No special tools required.

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

Hydraulic fluid barrels must stand for some time before the fluid is
removed from them. Never roll the barrels to where you will be draw
ing off the fluid. Clean bungs and filler lids as well as the area around
them before opening.

If possible, you should use a charging set to fill up the hydraulic

system. Never leave the reservoir lid open longer than necessary.

WK04_013_0603EN 633
 Maintenancecard
04−013
Page 2 of 6

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
Dispose of used filter elements in accordance with the relevant
regulations.

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

" Switch off the hydraulic pumps.

" Switch off the engine/motor.

" Dump the fluid pressure completely.

" Switch off the remote control.

Danger
The pressure accumulated in pressurized systems must be dumped.

" Secure the machine against being started by unauthorised

persons  if you have any key−operated switches, remove the
key and disconnect the supply voltage.

" Secure your work area and fix notices to the locked controls
and setting devices.

634 WK04_013_0603EN
 Maintenancecard
04−013
Page 3 of 6

Checking Replace the filter element if the red button on the contamination
indicator pops out again after being pressed in at operating
temperature.

WK04_013_0603EN 1

Checking and changing the pressure filter

" Bring the machine up to operating temperature (> 50° C).

" Set the maximum engine/motor speed.

" Press the red button on the pressure filter.

Note
The filter element is OK if the red button remains depressed.

The filter element must be replaced if the red button pops out again.

WK04_013_0603EN 635
 Maintenancecard
04−013
Page 4 of 6

Changing

WK04_013_0603EN 2

No. 0 Designation
1 Filter element
2 Filter housing

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

636 WK04_013_0603EN
 Maintenancecard
04−013
Page 5 of 6

" Undo the filter housing (2) and remove the filter element (1).

" Clean the filter housing (2) thoroughly with a clean rag.

" Install a new filter element.

Note
Before fitting new filter elements, you must check all O−rings and
other seals on the filter elements and replace them if damaged.

" Screw the filter housing back on (see the spare parts sheet for
the tightening torque).

Note
Check the level of the contamination indicator. Always refit the pro
tective lid on the contamination indicator each time this is checked.

WK04_013_0603EN 637
 Maintenancecard
04−013
Page 6 of 6

638 WK04_013_0603EN
 Maintenancecard
04−014
Page 1 of 4

04–014 Changing the ventilation This maintenance card describes how to change the ventilation filter
filter element element.

No further maintenance cards required.

No special tools required.

Maintenance
Ventilation filter for ... Filter element
indicator
water tank no no
fuel tank yes no
hydraulic fluid reservoir yes yes

Note
When a maintenance indicator is integrated into the screw cap on
the filter housing, you can use it to detect the latest time that the filter
element should be changed. Without a maintenance indicator,
change the filter elements when they appear very dirty.

WK04_014_0308EN 639
 Maintenancecard
04−014
Page 2 of 4

8
1
7
6

2 3 4 5

WK04_014_0308EN 1

No. 0 Designation
1 Filter element
2 3−stage maintenance indicator
3 Rotary knob, resets the maintenance indicator
4 Screw cap with maintenance indicator
5 Hydraulic fluid reservoir filter housing
6 Fuel/water tank filter housing
7 Screw cap without maintenance indicator
8 Filter element (optional)

640 WK04_014_0308EN
 Maintenancecard
04−014
Page 3 of 4

" Undo the screw cap from the filter housing.

" Remove the filter element from the filter housing.

Environmental protection
Dispose of used filter elements in accordance with the relevant
regulations.

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

" Clean the filter housing and the inside of the screw cap with a
clean cloth.

" When fitted, reset the 3−stage maintenance indicator by turn

ing the rotary knob anti−clockwise in the direction of the arrow.
å The 3−stage maintenance indicator jumps back to its orig

inal position.

" Insert a new filter element into the screw cap.

" Screw the screw cap with filter element inserted back onto the
filter housing.

WK04_014_0308EN 641
 Maintenancecard
04−014
Page 4 of 4

642 WK04_014_0308EN
 Maintenancecard
04−002
Page 1 of 4

04–002 Hoses This maintenance card describes how to check and replace the
hydraulic hoses. You will find the maintenance intervals in the main

tenance summary at the start of this chapter.

No further maintenance cards required.

No special tools required.

Note
Check all hoses (including hose fittings) with the machine running.
You must replace the hoses at the slightest sign of damage or even
mere indications of threatened damage.

Leaking hoses

10400800

Check hydraulic hoses

Dark and moist patches on the fitting are external signs of incipient
damage. Check:
− the hoses for kinks, cracks or a porous surface and
− whether the hoses have been laid without restrictions.

Note
Beware of strong sunlight, the action of heat and the effects of
chemicals.

WK04_002_0305EN 643
 Maintenancecard
04−002
Page 2 of 4

Flared screwed joints

10400100

Tighten until there is a clearly perceptible increase in force

" Check whether the flared screwed joints are tight.

Note
You may only tighten leaking flared screwed joints with the permitted
torque. Tighten the joint until you clearly feel an increase in the force
required if you do not have a torque wrench available. You must
replace these flared screwed joints if leaking continues.

Flared screwed joints

External Type Max. torque External Type Max. torque
diameter Md [Nm] diameter Md [Nm]
6 L 20 18 L 120
8 L 40 20 S 250
L 55 25 S 400
12
S 80 30 S 500
15 L 70 38 S 800
16 S 130

644 WK04_002_0305EN
 Maintenancecard
04−002
Page 3 of 4

Replacing hoses The procedure for replacing hoses is as follows:

" Shut down the machine and secure against unauthorized

starting.

" Fully dump any (residual) pressure in the hydraulic system.

Danger
Hydraulic hoses may be mechanically pre−stressed. There is a risk
of injury from whipping hoses.

" Take care when undoing the joints.

" Close the connection points with a plug immediately you have
removed the old hoses. No dirt may enter the hydraulic circuit
and the hydraulic circuit must not run empty.

Danger
Hoses should not be more than six years old, including a storage
time of two years. Take note of the date of manufacture on the hoses.

" Keep the hoses free from dirt.

" Fit the hoses to be free from bends or points of abrasion.

" Bleed the hydraulic system.

" Carry out a test run and inspect all hoses again after fitting new
hoses.

Environmental protection
Catch escaping fluid in a container and dispose of in an environmen
tally friendly manner.

WK04_002_0305EN 645
 Maintenancecard
04−002
Page 4 of 4

646 WK04_002_0305EN
 Maintenancecard
04−005
Page 1 of 2

04–005 Vacuum meter This maintenance card describes how to replace the vacuum meter
and how to remove the packing piece. You will find the service inter

vals in the maintenance summary at the start of this section.

No further maintenance cards required.

No special tools required.

Note
Replace the vacuum meter if it is mechanically damaged or if the
display is incorrect, e.g. there is an indication although the machine
is not running.

Caution
You must remove or open the packing piece once you have fitted the
new vacuum meter.

WK04_005_9501EN 647
 Maintenancecard
04−005
Page 2 of 2

" Unscrew the old vacuum meter from the vacuum filter.

" Screw the new vacuum meter onto the vacuum filter.

10402000

Venting the vacuum meter

" Open the vent by either cutting off the tip of the packing piece
or piercing the rubber stopper, depending on the design.

648 WK04_005_9501EN
 Maintenancecard
10−005
Page 1 of 4

10–005 Measuring the wall This maintenance card describes how to measure the wall thickness
thickness (Machines of delivery lines. You will find the maintenance intervals in the main

without transfer tube) tenance summary at the start of this chapter.

No further maintenance cards required.

The following special tools are required:

Wall thickness measuring device

Note
Delivery lines are subject to constant wear. Measurement of the wall
thickness is particularly important before starting on major contracts.
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 the right concrete
pressure if the wall thickness of the delivery line has decreased
below the minimum required, particularly if a blockage has built up.

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 layer of high wear resisting pipes
may flake off the inside of the pipe. The pipe can burst at points that
have suffered heavy wear.

WK10_005_9405EN 649
 Maintenancecard
10−005
Page 2 of 4

11000101

Tapping the delivery line with a hammer handle

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

Delivery line bends Uniform wear can be achieved by regularly rotating the delivery line
bends through 180°. The wear on the external radius of an elbow is
greater than that on the internal radius or on straight pipes. You
should, therefore, take special care when measuring the wall thick

ness of the external radius of an elbow.
The minimum wall thickness for bends is shown in the graph below.

11000200

650 WK10_005_9405EN
 Maintenancecard
10−005
Page 3 of 4

Measuring Follow the operating instructions supplied with the measuring device
when carrying out measurements. Do not measure the wall thickness
of the delivery line at just one point, but around the entire circum

ference of the delivery pipes.
The minimum wall thickness is shown in the graph below.

Caution
Pipes and elbows must be replaced as soon as the wall thickness
has declined to the value for the minimum wall thickness.
Putzmeister accepts no liability if the wall thickness is less than the
minimum wall thickness.

Note
As a rule it is possible to continue pumping with a concrete pressure
lower than that shown in the graph.

We should, however, draw your attention to the fact that the delivery
line is subject to varying loading as a result of the dynamic loading
during pumping. There is no general method for calculating the mini
mum wall thickness for this loading, which depends on the individual
circumstances, and so the delivery line can also burst at a concrete
pressure which is assumed still to be permissible.

Furthermore, the concrete pressure can rise to 85 bar in the event

ofblockages, meaning that the wall thickness will no longer be
adequate and the delivery line will burst.

WK10_005_9405EN 651
 Maintenancecard
10−005
Page 4 of 4

Graph Minimum wall thickness as a function of concrete pressure

[bar] 150

140

130

120

110

100

90

1
80

70

60

50

40

30

20

10

0
0,0 0,5 1,0 1,5 2,0 2,5 3,0 3,5 4,0 4,5 5,0
[mm]
1 Maximum concrete pressure

652 WK10_005_9405EN
 Maintenancecard
10−044
Page 1 of 2

10–044 Measuring the wall thick- This maintenance card describes how to measure the wall thickness
ness of two–layer pipes of two−layer delivery lines.

See also the maintenance cards:

Measuring the wall thickness

The following special tools are required:

Wall thickness measuring device, material no. 454460

Note
Observe all safety instructions in the machine−specific Operating
Instructions and in the Safety manual.

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

WK10_044_0805EN 653
 Maintenancecard
10−044
Page 2 of 2

Inspecting two–layer Inspect two−layer delivery pipes and delivery line elbows
delivery pipes and (DN125,max. concrete pressure 85 bar) as follows:
delivery line elbows
" Visual inspection for cracks. Replace in case of crack
formation.

" Measure the wall thickness at the measuring points P1 and P 2.

Replace if the wall thickness has fallen below the minimum
required (see table).

Type Minimum (mm)

No. DN 125
P1 P2
up to 85 bar
Twin Pipe Twin Cast
1.1 7.1 + 3.6 4.1 3.6
Delivery line elbow
1.2 7.0 + 2.0 7.0 3.0
2.1 2.5 + 2.0 2.5 3.3
2.2 2.5 + 2.0 2.5 4.9
Delivery pipe
2.3 5.6 + 3.0 3.7 3.7
2.4 5.6 + 3.0 3.7 3.1

1.1 – 1.2
Delivery line elbow
Measuring points
P1/P2
Minimum (seetable)

2.1 – 2.4
Delivery pipe
Measuring points
P1/P2
Minimum (seetable)

Extract from Esser Service Manual – EM 070190, see Technical Appendix

654 WK10_044_0805EN
 Maintenancecard
20−062
Page 1 of 2

20–062 Lubricating the placing This maintenance card describes how to lubricate all lubrication
boom (MX 36–4 Multi) points on the placing boom if you do not have a centralized lubrica

tion system. You will find the maintenance intervals in the mainten

ance summary at the start of 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 DIN51502,
NLGI Class2.

Lubrication intervals You should grease the lubrication points every 60 hours unless a
different interval is specified. You should apply the grease until you
can see it escaping.

WK20_062_0810EN 1

Lubrication diagram for the MX 36−4 Multi placing boom

WK20_062_0810EN 655
 Maintenancecard
20−062
Page 2 of 2

656 WK20_062_0810EN
 Maintenancecard
21−015
Page 1 of 2

21–015 Lubricating the boom This maintenance card describes the lubrication of all lubrication
pedestal (MXR) points on the boom pedestal if you do not have a centralized
lubrication system. You will find the maintenance intervals in the
maintenance summary at the start of 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 DIN51502,
NLGI Klasse2.

Lubrication intervals You should grease the lubrication points daily, unless a different
interval is specified. You should apply the grease until you can see it
escaping.

22100902

Slewing gear lubrication diagram

WK21_015_9604EN 657
 Maintenancecard
21−015
Page 2 of 2

658 WK21_015_9604EN
 Maintenancecard
25−002
Page 1 of 12

25–002 Replacing the delivery line This maintenance card describes how to replace the delivery line
and its seals. You will find the maintenance intervals in the mainten

ance summary at the start of this chapter.

See also the maintenance cards:

Measuring the wall thickness

The following special tools are required:

Feeler gauge 4mm

General The delivery line is subdivided into two divisions:

− Boom delivery line
− Tubular column delivery line

These comprise:
− Elbows
− Straight delivery pipes of uniform length (maximum 3 m)
− Adapter pipes (straight lengths of pipe which are manufactured
individually for each arm assembly to adapt the delivery line to the
length of the arms)

Wall thickness Measure the wall thickness of the delivery line to determine which
delivery pipes need to be replaced.
Maintenance card: Measuring the wall thickness

The starting points for laying the pipe on the boom are the hinge
pivot points. The straight sections of the delivery line run from pivot
point to pivot point. They are no more than 3 m long. Where necess

ary an adapter pipe is used for adapting the delivery line to each
arm length.

WK25_002_1004EN 659
 Maintenancecard
25−002
Page 2 of 12

Adapter pipe length plate

10 15

11 16
1
12

2 13
14
3 17
18
4 19
20
5

WK25_002_1004EN 1

660 WK25_002_1004EN
 Maintenancecard
25−002
Page 3 of 12

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)
Model (maximum permitted outside diameter
12
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)
Model (maximum permitted outside diameter
19
and wall thickness of the delivery line)
20 V1−V10: Pump−riser pipe adapter pipe lengths

WK25_002_1004EN 661
 Maintenancecard
25−002
Page 4 of 12

Ordering The length of the adapter pipes differs according to the machine and
boom. For re−ordering purposes, you should take the lengths and
mounting position of all the adapter pipes on your machine from the
adapter pipe length plate next to the rating plate or from the following
spare parts sheets:
− Boom delivery line:
Spare parts sheet group 25.0
− Tubular column−boom pedestal delivery line:
Spare parts sheet group 25.3

12501000

The adapter pipe length plate is located on the boom

When ordering adapter pipes you should always state:

− Machine number Example: 22/.....
− Mounting position L3.1
− Length in mm 1377 mm
− Diameter DN DN 125

Caution
You must not exceed the delivery line wall thickness specified on the
rating plate and in the machine card. The additional weight can
impair the machine’s stability.

Note
Should you wish to re−equip your machine to a delivery line of greater
wall thickness, the stability of your machine will have to be recalcu
lated and checked and approved by an authorized inspector.

662 WK25_002_1004EN
 Maintenancecard
25−002
Page 5 of 12

Tension–free The boom delivery line must be fitted with the arm assembly fully
assembly relieved of tension:
− The arm assembly is relieved of tension in the transport position if
each arm is resting loose on the mount provided.
− The arm assembly is not under tension when unfolded if each arm
is supported.

Caution
If the tension on the arm assembly is not fully relieved during fitting,
stresses may occur in the delivery line on movement of the placing
boom and consequential damage may be caused to the pipe
brackets and to the placing boom. Furthermore, the boom may
swing up and down during pumping operations causing the end
hose to swing violently and strike out.

Clearance A clearance of 4 mm must be maintained between the delivery pipes

over the whole of the delivery line, so that the weld−on rings can butt
against the couplings without play. This clearance is achieved either:
− automatically, through the use of a Cseal (triple−lip seal); or
− manually, by adjustment, using a feeler gauge.

WK25_002_1004EN 663
 Maintenancecard
25−002
Page 6 of 12

Seal C seals (triple−lip seals) are used where the delivery line runs in a
straight line and there is no rotational movement. The 4 mm clearance
is set automatically.

Caution
No triple−lip seals (Cseals) may be used in the pivot hinges of the
elbows.

A seals are used:

− if the delivery line does not run in a straight line;
− in the pivot hinges; and
− at the mounting coupling at the boom tip.
The spacing of 4 mm must be set using the feeler gauge.

Coupling Couplings with lever−operated closures must be secured with a

spring safety clip.

WK25_002_1004EN 2

Securing couplings with lever−operated closures

Couplings with a threaded closure are closed using self−locking

nuts. These nuts must not be re−used, but must be replaced each
time the coupling is fitted.

Caution
You must not fit aluminium couplings in the pivot hinges of the elbows.
Aluminium couplings have a higher wear rate than steel couplings
and are worn away more quickly by the rotational movement.

664 WK25_002_1004EN
 Maintenancecard
25−002
Page 7 of 12

Fitting an A seal

4mm

11000301

Set the spacing with the feeler gauge

" Push the A seal over the fixed delivery pipe.

" Lay the delivery pipe to be attached in the pipe brackets and
push it up to the fixed delivery pipe.

" Set the spacing of 4mm between the delivery pipes using a
feeler gauge.

" Fix the delivery pipe to be attached in the pipe brackets.

" Push the A seal over the two weld−on rings.

" Fit the coupling and secure it.

WK25_002_1004EN 665
 Maintenancecard
25−002
Page 8 of 12

Caution
No triple−lip seals (Cseals) may be used in the pivot hinges.

Fitting a C seal

4mm

11000302

The spacing is set automatically by the seal ring

" Push the Cseal over the weld−on ring of the fixed delivery
pipe.

" Lay the delivery pipe to be attached in the pipe brackets and
push it up to the fixed delivery pipe.

" Push the delivery pipe to be attached as far as the stop in the
seal ring.

" Fix the delivery pipe to be attached in the pipe brackets.

" Fit the coupling and secure it.

666 WK25_002_1004EN
 Maintenancecard
25−002
Page 9 of 12

Boom delivery line The starting points for laying the pipe on the boom are the hinge
pivot points.

" Grease all couplings and seals well internally before assembly.

Note
Use a lithium soap base multipurpose grease labelled K2K.

" Install the elbows in the mounting couplings at the pivot points.

" Align the elbows such that the straight delivery pipes can be
connected without tension.

" Fix the elbows.

" Install the fixed length delivery pipes.

" Install the adapter pipes last.

WK25_002_1004EN 667
 Maintenancecard
25−002
Page 10 of 12

Delivery pipe on It is easiest to fit the delivery pipes to the tubular column when the
tubular column tubular column is still lying on the ground.

Note
Start by fitting the delivery pipes on the lower part of the tubular
column.
You can fully pipe a tubular column using delivery pipes 3 m long.

" Grease all couplings and seals well internally before assembly.

Note
Use a lithium soap base multipurpose grease labelled K2K.

1 2

Aligning the delivery pipe

" Lay a 3*m long delivery pipe (1) onto the holders in the tubular
column (2) in such a way that the end of the delivery pipe is
level with the lower end of the tubular column.

668 WK25_002_1004EN
 Maintenancecard
25−002
Page 11 of 12

Fitting the delivery pipe

" Fasten the delivery pipe to the holders using the pipe
brackets(1).

" Proceed in the same way when you attach the next delivery
pipe to the fixed delivery pipe.

WK25_002_1004EN 669
 Maintenancecard
25−002
Page 12 of 12

Boom pedestal
delivery pipe

11000302

Boom pedestal delivery pipe

" Fasten the elbow (4) to the boom pedestal as illustrated above.

" Fasten the delivery pipe (2) to the elbow using a mounting
coupling (3).

" Fasten the mounting coupling to the holder (1) in the boom
pedestal. Make sure that the bolted connections are free to
move in the slots of the holder.

670 WK25_002_1004EN
 7 Index of key words

In this section you will find the most important key words with the
number of the page on which you will find the key word as a heading
in the left margin. This Index of key words is listed alphabetically by
the main concepts. These are subdivided into associated sub−con

cepts, marked with a dash.

BP11_001_0201EN
 Indexofkeywords

Technical data, 3
4
Climbing hydraulic system, 5
53

A
Unfolding, 5
31
Climbing system remote control, 5
55
A seal, 4
34 Boom control block, Inspection, 5
6
Extending the delivery line, 5
72

Fastening the delivery line, 5
72
Abbreviations, G
15 Boom movements, 5
16

Inserting the horizontal bolt, 5
68
Accessories and attachments, 2
13
Danger zone, 5
18

Limit parameters, 5
52

Hand signals, 5
21, 5
24
After Sales Service personnel, Defini-
Moving the climbing unit, 5
58
tion of terms, 2
3
High−voltage lines, 5
19

Placing the wedges, 5
71

Prohibited activities, 5
16
Agitator gearbox, Transmission oil,
Preconditions, 5
48

Signalling with the horn, 5
20
6
11
Releasing the climbing carriage, 5
61

Spontaneous retraction of the boom
Air hose, Connecting, 4
79
Removing the wedges, 5
65
cylinders, 5
22

Repeating, 5
68
Arm assembly
Uncontrolled boom movements, 5
23

Terminating the climbing procedure,

Definition of terms, 2
1 Boom pedestal 5
69

Fitting, 4
49
Definition of terms, 2
1
Withdrawing the horizontal bolt, 5
70

Lowering onto the transport frame,
Lowering onto the transport frame,
4
83 Climbing cylinder, 3
27
4
85

Bleed, 5
57
Assembly, 4
8
Removal from the tubular column,

Ballastable cruciform base, 4
18 4
84 Climbing system

Bottom plates, 4
44 Bottom plates, 3
36
Description of the functions, 3
3, 3
28

Climbing system, 4
36
Fitting, 4
44
Fitting, 4
36

Corner brackets, 4
47
Technical data, 3
4
Technical data, 3
4

Cruciform base on foundation anchor, Climbing unit, 5
58
4
11 Cold weather, 2
36

Cruciform base onto ballastable cruci
C Commissioning, 5
1
form base, 4
18
C seal, 4
33 Components

Delivery pipe on tubular column, 6
68

Foundation anchor, 4
11 Cable remote control, 3
19, 5
10
Dimensions, 3
4

Ladder element, 4
38
Boom speed, 5
13
Electrical components, 2
53

Placing the wedges, 4
48
Connecting, 4
76
Overview, 3
1

Stationary delivery line, 4
59 Centralized lubrication system
Safety−relevant components, 2
50

Tubular column, 4
25
Grease, 6
12
Weight, 3
4

Tubular column elements, 4
28
Low temperature grease, 6
12 Compressed air cleaning, 2
45
Authorized inspector, Definition of Cleaning, 2
43, 5
80 Concrete brake, 3
41, 5
44
terms, 2
3
Cleaning agents, 2
44 Concrete pump, Definition of terms,
Auxiliary personnel, Definition of
Compressed air, 2
45 2
1
terms, 2
2
Compressed air cleaning, 5
80
Connecting, 4
68

Hazards, 2
44

Air hose, 4
79

Post−cleaning procedure, 2
46
B
Pressurized water cleaning, 5
83

Cable remote control, 4
76

Delivery line, 4
68
Ballastable cruciform base, Fitting,
Suction cleaning, 5
81

Electrical connection, 4
73
4
18
Tapping the delivery line, 5
82

Squeeze valve, 4
79
Base structure, Definition of terms, Cleaning agents, 2
44
Control block, Boom, 3
26
2
1 Clearances
Control cabinet, 3
16
Blockages, 2
38
From high−voltage lines, 2
21

To delivery lines, 2
39 Control devices
Boom
Boom control block, 3
26

Bounce, 5
40 Climbing, 5
48

Cable remote control, 3
19

Description of the functions, 3
3
Arresting the lower climbing carriage,

Chain hoist remote control, 3
21

Favourable boom position, 5
41 5
63

Climbing system remote control, 3
22

Folding, 5
85
Arresting the upper climbing carriage,
5
69
Control cabinet, 3
16

Impermissible working range, 5
38
Squeeze valve control panel, 3
18

Rest position, 5
91
Bleeding the climbing cylinders, 5
57

Boom climbing position, 5
52
Symbols, 3
13

i
 Indexofkeywords

Control panel, Squeeze valve, 3
18
Truck mixer driver, 2
3

Copyright, 1
2
Working area, 2
4, 2
6
E
Corner bearing load, 2
28 Delivery line Earthing, 2
24

Corner brackets, 3
34

Closing with a squeeze valve, 3
37 Electric motor, Direction of rotation,

Connecting, 4
68 4
73, 4
78

Fitting, 4
47

Danger zone, 4
72 Electrical components, 2
53

Hole in floor, 3
34

Description of the functions, 3
3

Placing the wedges, 4
48, 5
71 Electrical connection, 4
73

Fastening, 6
69

Removing the wedges, 5
65 Electrical equipment, 3
5

Measuring the wall thickness, 6
53

Technical data, 3
4

Measuring the wall thickness (Machi
Electrical power, 2
52
Cruciform base, 3
31 nes without transfer tube), 6
49
Power at the construction site, 2
53

Fitting on foundation anchor, 4
11
Pipe bracket, 6
69
Electrostatic charging, 2
24

Fitting onto ballastable cruciform base,
Replacing, 6
59
4
18
Tapping, 5
82 Emergency operation, 5
14

Technical data, 3
4
Delivery line systems, 2
37 EMERGENCY STOP button, 2
20,

Template, 3
32 2
34, 3
23, 5
5

Clearance to delivery lines, 2
39

With ballast, 3
33 EMERGENCY STOP function, 5
4

Continuation delivery lines, 2
39

Danger zone, 2
8 Emissions, Noise, 2
55
D
Definition of terms, 2
1 End hose, 2
35, 3
40, 5
42

Fastening delivery lines, 2
39
Concrete brake, 3
41, 5
44
Danger zone, 2
4, 2
7
Opening the delivery line, 2
39
Danger zone, 2
8, 2
35, 5
42

Boom movements, 5
18
Securing delivery lines, 2
37
Dual−section end hose, 3
43

Delivery line, 4
72
Shutting−off, diverting, cleaning, 2
40
Extending, 2
12

Delivery line systems, 2
8
Suitable delivery line, 2
37
Impermissible end hose, 2
12

End hose, 2
8, 2
35
Tightness and blockages, 2
38
Protective bell, 3
43

Hopper, 2
8
Delivery pipe
Retaining rope, 3
42

Machine, 2
8

Aligning, 6
68
With flow restrictor, 3
41

Placing boom, 2
7

Boom pedestal, 6
70 Exhaust fumes, 2
56

Pumping operations, 5
42

Fitting on the tubular column, 6
68

Stationary delivery line, 4
60 Extensions, End hose and placing

Support legs and support feet, 2
7 Description of the functions, 3
3 boom, 2
12

Boom, 3
3
Definition of terms

Climbing system, 3
3, 3
28

After Sales Service personnel, 2
3

Arm assembly, 2
1

Delivery line, 3
3 F

Hydraulic control, 3
3

Authorized inspector, 2
3 Face mask, 2
18

Auxiliary personnel, 2
2 Designated use, 2
9
Fastening, Stationary delivery line,

Base structure, 2
1
Inspection intervals, 2
10
4
63

Boom pedestal, 2
1 Dimensions, 3
4
Filter

Concrete pump, 2
1
Components, 3
4

Boom filter, 5
3

Danger zone, 2
4, 2
7
Hole in floor, 3
34

Suction filter, 5
2

Delivery line systems, 2
1 Disassembly
Vacuum meter, 5
2

Hoseman, 2
2
Ladder element, 4
90

Machine, 2
2 Filter change

Tubular column, 4
87

Machine operator, 2
2
Pressure filter, 6
33

Working platform, 4
86

Maintenance, 2
3
Suction filter, 6
27
Discharge voltage pattern, 2
21
Ventilation filter, 6
39

Operator, 2
2

Place of work, 2
4, 2
6 Downpipe, 4
66 Filter functions, 5
2

Placing boom, 2
1 Driving, 2
30
Suction filter, 5
2

Qualified personnel, 2
3 Dual–section end hose, 3
43 Fitting

Signaller, 2
2
Arm assembly, 4
49

Subject expert, 2
3
Working platform, 4
39

Truck mixer, 2
1
Flared screwed joint, 6
5

ii
 Indexofkeywords

Flash over, 2
23
Responsibility of the machine operator,

Flow restrictor on the end hose, 3
41
L 2
14

Foundation anchor, Fitting, 4
11 Ladder, Ascension prohibited, 4
72 Maintenance, Definition of terms, 2
3

Fumes, Exhaust, 2
56 Ladder element Maintenance and special work, 2
47

Fitting, 4
38 Maintenance cards
Function checks, 5
2, 6
25

Removing, 4
90
Changing the hydraulic fluid, 6
19

Boom control block inspection, 5
6

Technical data, 3
4
Changing the pressure filter element,

Emergency operation, 5
7

EMERGENCY STOP function, 5
4 Liability, Exclusion, 2
13 6
33
Lifting loads, 2
11, 2
25
Changing the suction filter element,

Filter function, 5
2
6
27
Functional fluids, 2
56, 5
1, 6
6 Lifting points, 2
32, 4
2
Changing the ventilation filter element,

Arm assembly, 4
6 6
39

Boom pedestal with tubular column,
Function checks, 6
25
H 4
4
Hoses, 6
43

Boom pedestal without tubular column,
Hand signals, 5
21
Lubricating the boom pedestal, 6
57
4
3

Boom movements, 5
24
Lubricating the MX 36−4 Multi placing

Climbing column, 4
2 boom, 6
55

Pumping operations, 5
24

Cruciform base, 4
2
Measuring the wall thickness, 6
53
Hearing protectors, 2
17
Tubular column element, 4
2
Measuring the wall thickness (Machi

High–pressure delivery, 2
13 Limit parameters, Tubular column nes without transfer tube), 6
49
High–voltage lines, 2
21, 5
19 length, 4
9
Replacing the delivery line, 6
59

Clearances, 2
21 Loading, 2
25, 2
32
Vacuum meter, 6
47

High−voltage warning device, 2
23
Lifting points, 2
32
Visual checks, 6
17

Procedure in the event of a flash over, Lubricant analysis, 6
6, 6
8 Maintenance intervals, 6
1
2
23
Lubricant recommendation Measuring the wall thickness, 6
53
High–voltage warning device, 2
23
Machines without transfer tube, 6
49

Agitator gearbox, 6
11
Hole in floor, Dimensions, 3
34
Engine oil, 6
11 Minimum wall thicknesses, 6
52
Hopper, Danger zone, 2
8
General, 6
9 Mobile machines, 2
26
Hoseman, Definition of terms, 2
2
Greases, 6
12
Set−up site, 2
26

Hydraulic fluids, 6
13
Supporting ground, 2
27
Hoses, Maintenance, 6
43

Low temperature grease, 6
12
Hydraulic control, Description of the MX 36–4 Multi, Lubrication, 6
55

Oils, 6
11
functions, 3
3
Pump tube grease, 6
12
Hydraulic fluid, Full fluid change,
6
19

Rotor gearbox, 6
11

Slewing gear transmission, 6
11
N
Hydraulic hoses, 2
55
Transfer gearbox, 6
11 Noise emission measurement, 3
5
Hydraulic pack, Technical data, 3
5

Transmission oil, 6
11 Noise emissions, 2
55
Lubrication
Hydraulic systems, 2
54

Grease, 6
12

MXR boom pedestal, 6
57 O
I
Placing boom MX 36−4 Multi, 6
55 Operating Instructions, 2
15

Icons, 1
3 Operating procedures, 2
15, 2
16

Impermissible end hose, 2
12 M Operator, Definition of terms, 2
2

Impermissible working area, 2
6, Machine Overview of the components, 3
1

2
12
Danger zone, 2
8
Inspection intervals, 2
10
Definition of terms, 2
2

Moving machine components, 2
42
P
Instructions for laying the line, Statio-
nary delivery line, 4
61
Observing, 2
42 Personal protective equipment, 2
17
Machine operator Personnel, 2
14

Definition of terms, 2
2
Qualifications, 2
14

iii
 Indexofkeywords

Requirements, 2
14 Sinking of the boom, 5
23

Responsibility of the machine operator,
R SK delivery line system, 4
67
2
14 Rating plate Slewing circle, 3
11
Pipe bracket, 6
69
Boom, 3
7
Stop, 3
11
Place of work, 2
4, 2
6, 3
5
Machine, 3
6
Slewing gear transmission, Transmis-

Place of work − hoseman, 2
6 Reaches, 3
9 sion oil, 6
11

Place of work − machine operator, 2
6
Extending, 2
11
Software, 2
51

Place of work − truck mixer driver, 2
6 Ready for operation

Pumping operations, 2
41 Special work, 2
47

Checking, 2
19
Placing boom, 2
33, 2
36
Rendering the machine ready, 2
19 Squeeze valve, 3
37, 5
45

Climbing, 2
13
Closing the delivery line, 3
37
Regulations, 2
15, 2
16

Danger zone, 2
7
Connecting, 4
79
Remote control, 2
41, 5
9
Control panel, 3
18

Definition of terms, 2
1

Chain hoist, 3
21

Extending, 2
12 Starting up, With cable remote con-

Climbing, 3
22, 5
55

Procedure in storms, 2
36 trol, 5
10
Removal, 4
80

Unfolding, 2
33 Stationary delivery line, 4
59

Wind speeds, 2
36 Removing obstacles, 2
11
Danger zone, 4
60

Working on the placing boom, 2
50 Respiratory protection, 2
18
Downpipe, 4
66
Power, 2
53 Responsibility of the machine opera-
Fastening, 4
63
Power at the construction site, 2
53 tor, 2
14
Fixed point, 4
64

Horizontal, 4
63
Power supply, Supply cable, 3
5 Restrictions

Instructions for laying the line, 4
61
Profiled ring joint, 6
5
Bad weather, 5
17

Riser, 4
66

Boom movements, 5
17
Protective equipment, 2
17, 2
51
SK delivery line system, 4
67

Cold weather, 2
36, 5
17

Face mask and respiratory protector,
Vertical and inclined, 4
65

Storm, 5
17
2
18 Stationary machines, 2
25

Wind, 5
17

Hearing protectors, 2
17
Lifting machines, 2
25

Protective gloves, 2
18 Retaining hooks, 5
33

Loading, 2
25

Protective goggles, 2
18 Retaining rope, 3
42
Set−up site, 2
25

Safety harness, 2
18 Riser, 4
66
Transporting, 2
25

Safety helmet, 2
17
Rotor gearbox, Transmission oil, 6
11 Storm, 2
36

Safety shoes, 2
17
Rotor pump, Measuring the wall thick- Subject expert, Definition of terms,
Protective gloves, 2
18
ness, 6
49 2
3
Protective goggles, 2
18
Rotor pumps, Pump tube grease, Supply cable, 3
5
Pump tube in rotor pumps, Grease, 6
12 Support legs and support feet, Dan-
6
12
ger zone, 2
7
Pumping operations, 2
41, 5
39

Boom, 5
40
S Supporting ground, 2
27

Corner bearing loads, 2
28

Calm pumping, 5
40 Safety equipment, 2
51

Favourable boom position, 5
41 Supports, 2
29
Safety harness, 2
18

Hand signals, 5
24 Symbols, 1
3, 3
13, 3
14
Safety helmet, 2
17

Safety, 2
41 Symbols for the control system, 3
13,
Safety shoes, 2
17 G
1
Safety–relevant components, 2
50
Q
Qualifications, 2
14
Seal ring, Between delivery pipes,
4
33, 4
69
T
Qualified personnel, Definition of Set–up site, 2
25, 2
26 Technical data, 3
4
terms, 2
3
High−voltage lines, 2
21
Cruciform base template, 3
32

Supports, 2
29
Hydraulic pack, 3
5

Noise emission measurement, 3
5
Signaller, Definition of terms, 2
2

Slewing circle, 3
11

iv
 Indexofkeywords

Supply cable, 3
5 Use contrary to designated use, 2
11

Technical terms, G
15
Accessories and attachments, 2
13

Climbing the placing boom, 2
13
Temperatures, Restrictions, 2
36

Exclusion of liability, 2
13
Tightening torques
Extending the reach, 2
11

Flared screwed joint, 6
5
Extensions, 2
12

General, 6
3
High−pressure delivery, 2
13

Profiled ring joint, 6
5
Impermissible end hose, 2
12

Set screws and nuts, 6
4
Impermissible working area, 2
12

Torque wrench, 3
45
Lifting loads, 2
11

Torque wrench set, 3
45
Removing obstacles, 2
11
Torque wrench, 3
45
Transporting goods, 2
11
Torque wrench set, 3
45
Torque wrench socket, 3
45 V
Towing, 2
31
Vacuum meter, 5
2
Transfer gearbox, Transmission oil,
Venting, 6
47
6
11
Visual checks, 6
17
Transmission oil

Agitator gearbox, 6
11

Rotor gearbox, 6
11 W

Slewing gear transmission, 6
11

Transfer gearbox, 6
11 Water, 2
46
Transport, 4
1 Weights, 3
4
Transport frame, 3
10, 4
1 Welding, 2
49

Lowering the arm assembly onto the Wind speeds, 2
36
transport frame, 4
83 Working area, 2
4, 2
6

Lowering the boom pedestal, 4
85
Impermissible working area, 2
5, 2
6,

Technical data, 3
4 2
12
Transporting, 2
25
Permitted working area, 2
5
Transporting goods, 2
11 Working platform
Triple–lip seal, 4
33, 4
69
Fitting, 4
39

Removing, 4
86
Truck mixer, 2
42

Technical data, 3
4

Definition of terms, 2
1
Working range
Truck mixer driver, 2
42

Impermissible working range, boom,

Definition of terms, 2
3
5
38
Tubular column
Overlaps, 5
20

Fitting, 4
25
Working with the machine

Removing, 4
87

Before starting work, 2
19

Technical data, 3
4

Checking that the machine is ready for
Tubular column elements, Connec- operation, 2
19
ting, 4
28
Rendering the machine ready for ope

Two–layer delivery line elbow, Inspec- ration, 2
19
tion, 6
54
Two–layer delivery pipe, Inspection,
6
54

U
Uncontrolled boom movements, 5
23

v
 8 Glossary

This chapter illustrates the control system symbols (icons for con

crete pumps) and explains the abbreviations and technical terms
that are used in Putzmeister Operating Instructions.

BP14_001_0501EN
 Glossary

G–1 Symbols for concrete pumps in accordance with German Mechanical Engineering
Association Standard (VDMA 24119)

G–1.1 General (for key, see page G — 7)

3701 3713 3725 5008 6012 7005

3702 3714 4001 6001 6013 7006

3703 3715 4002 6002 6014 7007

3704 3716 4003 6003 6015 7008

3705 3717 4004 6004 6016 7009

3706 3718 5001 6005 PM6017 7010

3707 3719 5002 6006 PM6018 7011

3708 3720 5003 6007 PM6019 7012

3709 3721 5004 6008 7001 8001

3710 3722 5005 6009 7002 8002

3711 3723 5006 6010 7003 8003

3712 3724 5007 6011 7004 8004

BP14_003_0501EN G1
 Glossary

8005 10005 10017 12001 12013 12025

8006 10006 10018 12002 12014 12026

8007 10007 10019 12003 12015 12027

8008 10008 10020 12004 12016 12028

8009 10009 10021 12005 12017 12029

9001 10010 10022 12006 12018 12030

9002 10011 10023 12007 12019 12031

9003 10012 10024 12008 12020 12032

10001 10013 10025 12009 12021 12033

10002 10014 11001 12010 12022 12034

10003 10015 11002 12011 12023 12035

10004 10016 11003 12012 12024 12036

G2 BP14_003_0501EN
 Glossary

12037 12043 12049 12055 13004 14003

12038 12044 12050 12056 PM13005 15001

12039 12045 12051 12057 PM13006 15002

12040 12046 12052 13001 PM13007 15003

12041 12047 12053 13002 14001

12042 12048 12054 13003 14002

G–1.2 Support (for key, see page G — 10)

2601 2604 2607 2610 2613 2616

2602 2605 2608 2611 2614 2617

2603 2606 2609 2612 2615

BP14_003_0501EN G3
 Glossary

G–1.3 Boom, 2–arm (for key, see page G — 10)

1201 1203 1205 1207 1209 1211

1202 1204 1206 1208 1210

G–1.4 Boom, 3–arm (for key, see page G — 10)

1301 1304 1307 1310 1313 1316

1302 1305 1308 1311 1314

1303 1306 1309 1312 1315

G–1.5 Boom, 4–arm (for key, see page G — 11)

1401 1406 1411 1416 1421 1426

1402 1407 1412 1417 1422 1427

1403 1408 1413 1418 1423

1404 1409 1414 1419 1424

1405 1410 1415 1420 1425

G4 BP14_003_0501EN
 Glossary

G–1.6 Boom, 5–arm (for key, see page G — 12)

1501 1506 1511 1516 1521 1526

1502 1507 1512 1517 1522 1527

1503 1508 1513 1518 1523 1528

1504 1509 1514 1519 1524 1529

1505 1510 1515 1520 1525 1530

G–1.7 Boom, 6–arm (for key, see page G — 12)

PM1601 PM1604 PM1607 PM1610 PM1613 PM1616

PM1602 PM1605 PM1608 PM1611 PM1614

PM1603 PM1606 PM1609 PM1612 PM1615

BP14_003_0501EN G5
 Glossary

G–1.8 Ergonic Boom Control, 3–arm (for key, see page G — 13)

PM1301 PM1303 PM1305 PM1307 PM1309

PM1302 PM1304 PM1306 PM1308

G–1.9 Ergonic Boom Control, 4–arm (for key, see page G — 13)

PM1401 PM1403 PM1405 PM1407 PM1409 PM1412

PM1402 PM1403A PM1406 PM1407A PM1410 PM1413

PM1402A PM1404 PM1406A PM1408 PM1411 PM1414

G–1.10 Ergonic Boom Control, 5–arm (for key, see page G — 14)

PM1501 PM1503 PM1505 PM1507 PM1509 PM1512

PM1502 PM1503A PM1506 PM1507A PM1510 PM1513

PM1502A PM1504 PM1506A PM1508 PM1511 PM1514

G–1.11 Ergonic Boom Control, 6–arm (for key, see page G — 14)

PM1601 PM1603 PM1605 PM1607 PM1609 PM1611

PM1602 PM1604 PM1606 PM1608 PM1610

G6 BP14_003_0501EN
 Glossary

G–2 Key to the symbols for concrete pumps

G–2.1 General
3701 Increase/reduce output using rotarycontroller 5001 Agitator, hopper

3702 Increase/reduce output using toggleswitch 5002 Agitator clockwise rotation

3703 Increase output 5003 Agitator anticlockwise rotation

3704 Reduce output 5004 Hopper empty

3705 Reverse pumping 5005 Hopper full

3706 Pumping On 5006 Agitator cut−out

3707 Pumping Off 5007 Hopper level control

3708 Pumping On−Off 5008 High−pressure agitator

3709 Pumping standby 6001 Hydraulic oil excess temperature

3710 Pumping in general 6002 Radiator

3711 Rotor pump in general 6003 Radiator1

3712 Pump flow meter 6004 Radiator2

3713 Full output 6005 Fill accumulator

3714 Half output 6006 Dump accumulator pressure

3715 High pressure pump 6007 Hydraulic cylinder blockage

3716 Pump control system 6008 High−pressure hydraulic system

3717 Change−over 6009 Insufficient hydraulic fluid

3718 Stroke pulse change−over 6010 Hydraulic fluid

3719 Stroke correction 6011 Air

3720 Change−over delay 6012 High pressure

3721 Screw conveyor1 anticlockwise rotation 6013 Accumulator pressure

3722 Screw conveyor1 clockwise rotation 6014 Filter element

3723 Screw conveyor2 anticlockwise rotation 6015 Rod side

3724 Screw conveyor2 clockwise rotation 6016 Piston side

3725 Screw conveyor PM6017 Hydraulic fluid filter water level STOP

4001 Centralised grease lubrication, manual PM6018 Hydraulic fluid filter water level warning

4002 Centralised grease lubrication, automatic PM6019 Hydraulic fluid filter contamination warning

4003 Centralised oil lubrication, manual 7001 Working light

4004 Centralised oil lubrication, automatic 7002 Lighting

BP14_004_0501EN G7
 Glossary

7003 Control cabinet lighting 10010 Speed sensor

7004 Toolbox lighting 10011 Increase speed

7005 Rear light 10012 Reduce speed

7006 Spirit level lighting 10013 Engine air filter

7007 Flashing beacon 10014 Electric motor in general

7008 Acknowledge flashing beacon 10015 Silent

7009 Brake light 10016 Reduced fuel consumption

7010 Side marker lamps container 10017 Tank monitoring

7011 Lighting mast 10018 Coolant level

7012 Diagnostics lamp 10019 Diesel engine control

8001 Machine diagnostics connector 10020 Starter

8002 Read−out data 10021 Manual throttle lever

8003 Read−in data 10022 Start−up relief (soft start)

8004 Read−in minimum value 10023 Diesel supply On

8005 Reset memory contents (save) 10024 Fuel

8006 Cancel memory contents (clear) 10025 Fuel filter draining

8007 Start 11001 Radio remote control

8008 Read−in maximum value 11002 Remote control in general

8009 Menu 11003 Plug in remote control

9001 Control cabinet 12001 Horn

9002 Diagnostics socket 12002 Fault in general

9003 Teleservice 12003 Acknowledge

10001 Diesel engine On 12004 Battery

10002 Diesel engine Off 12005 Battery charging device

10003 Engine oil excess temperature 12006 EMERGENCY SHUT−DOWN activated

10004 Cooling water excess temperature 12007 Acknowledge EMERGENCY SHUT−DOWN

10005 Acknowledge cooling water excess temperature 12008 Stop

10006 Engine oil pressure 12009 Test operation

10007 V−belt failure 12010 Vibrator On

10008 Increase speed, reduce speed 12011 Vibrator Off

10009 Speed 12012 Vibrator

G8 BP14_004_0501EN
 Glossary

12013 Potentiometer 12042 Lock

12014 Off−On 12043 2ndlevel

12015 On 12044 Circuit1

12016 Off 12045 Circuit2

12017 Fast (e.g.acceleration) 12046 Circuits1+2

12018 Normal (e.g.acceleration) 12047 High−pressure limit

12019 Compressor 12048 Flap/closure closed

12020 Compressor On−Off 12049 Flap/closure open

12021 Motor vehicle fuse 12050 Generator

12022 Cable drum 12051 Boom on cradle

12023 Operating hours meter 12052 Manual operation

12024 Operating position 12053 Electrical levelling

12025 Electrical power 12054 See Operating Instructions

12026 Automatic/manual 12055 Wear measurement

12027 Automatic operation 12056 Water

12028 Close shut−off device 12057 Overhead roll−and−fold boom

12029 Open shut−off device 13001 Power take−off

12030 Water tank heating 13002 Truck in general

12031 Cleaning 13003 Plan view

12032 Levelling control in general 13004 Brake in general

12033 Excess pressure PM13005 Driving

12034 Fuse test PM13006 Lifting axle raised

12035 Timer relay PM13007 Lifting axle not raised

12036 Right side 14001 Mixer in general

12037 Left side 14002 Drain mixer

12038 Concrete brake 14003 Activate mixer

12039 Buzzer 15001 Water glass dosing pump

12040 Container 15002 Flushing water pump

12041 Position at the machine 15003 High−pressure water pump

BP14_004_0501EN G9
 Glossary

G–2.2 Support
2601 Support leg/foot retract/extend 2610 Support leg working light

2602 Extend support leg 2611 Support leg retract/extend

2603 Retract support leg 2612 Support foot retract/extend

2604 Lower support foot 2613 Side marker lamps support leg

2605 Raise support foot 2614 Working range on the right

2606 Swing out right support leg 2615 Working range on the left

2607 Swing in right support leg 2616 Enable stability monitoring

2608 Swing out left support leg 2617 Stability monitoring

2609 Swing in left support leg

G–2.3 Boom, 2–arm

1201 Boom in general 1207 Slew boom to the left

1202 Arm 1 up 1208 Slew boom to the right

1203 Arm 1 down 1209 Move arms

1204 Arm 2 up 1210 Move arms switched off

1205 Arm 2 down 1211 Slewing gear activated

1206 Boom activated

G–2.4 Boom, 3–arm

1301 Boom in general 1309 Slew boom to the left

1302 Arm 1 up 1310 Slew boom to the right

1303 Arm 1 down 1311 Move arms

1304 Arm 2 up 1312 Move arms switched off

1305 Arm 2 down 1313 Slewing gear activated

1306 Arm 3 up 1314 Slew boom to the right switched off

1307 Arm 3 down 1315 Slew boom to the left switched off

1308 Boom activated 1316 Arm1 down switched off

G10 BP14_004_0501EN
 Glossary

G–2.5 Boom, 4–arm

1401 Boom in general 1415 Slewing gear activated

1402 Arm 1 up 1416 Arms up switched off

1403 Arm 1 down 1417 Slew boom to the left switched off

1404 Arm 2 up 1418 Slew boom to the right switched off

1405 Arm 2 down 1419 Arm1 down switched off

1406 Arm 3 up 1420 Arms up switched on

1407 Arm 3 down 1421 Tilt switch, arm1 circuit1

1408 Arm 4 up 1422 Tilt switch, arm1 circuit2

1409 Arm 4 down 1423 Tilt switch, arm2 circuit1

1410 Boom activated 1424 Tilt switch, arm2 circuit2

1411 Slew boom to the left 1425 Pressure switch, arm1 circuit1

1412 Slew boom to the right 1426 Pressure switch, arm1 circuit2

1413 Move arms 1427 Unfolding position

1414 Move arms switched off

BP14_004_0501EN G11
 Glossary

G–2.6 Boom, 5–arm

1501 Boom in general 1516 Move arms

1502 Arm 1 up 1517 Move arms switched off

1503 Arm 1 down 1518 Slew boom to the left switched off

1504 Arm 2 up 1519 Slew boom to the right switched off

1505 Arm 2 down 1520 Arm1 down switched off

1506 Arm 3 up 1521 Arms up switched on

1507 Arm 3 down 1522 Tilt switch, arm1 circuit1

1508 Arm 4 up 1523 Tilt switch, arm1 circuit2

1509 Arm 4 down 1524 Tilt switch, arm2 circuit1

1510 Arm 5 up 1525 Tilt switch, arm2 circuit2

1511 Arm 5 down 1526 Pressure switch, arm1 circuit1

1512 Boom activated 1527 Pressure switch, arm1 circuit2

1513 Slew boom to the left 1528 Unfolding position

1514 Slew boom to the right 1529 Arm5 switched on

1515 Slewing gear activated 1530 Arm5 switched off

G–2.7 Boom, 6–arm

PM1601 Boom in general PM1609 Arm 4 down

PM1602 Arm 1 up PM1610 Arm 5 up

PM1603 Arm 1 down PM1611 Arm 5 down

PM1604 Arm 2 up PM1612 Arm 6 up

PM1605 Arm 2 down PM1613 Arm 6 down

PM1606 Arm 3 up PM1614 Boom activated

PM1607 Arm 3 down PM1615 Slew boom to the left

PM1608 Arm 4 up PM1616 Slew boom to the right

G12 BP14_004_0501EN
 Glossary

G–2.8 Ergonic Boom Control, 3–arm

PM1301 Move end hose PM1306 Unfold the placing boom

PM1302 End hose forwards PM1307 Fold the placing boom

PM1303 End hose back PM1608 End hose to the left

PM1304 End hose up PM1309 End hose to the right

PM1305 End hose down

G–2.9 Ergonic Boom Control, 4–arm

PM1401 Move end hose PM1407 Fold the placing boom

PM1402 End hose forwards PM1407A Fold the placing boom (USA)

PM1402A End hose forwards (USA) PM1408 End hose to the left

PM1403 End hose back PM1409 End hose to the right

PM1403A End hose back (USA) PM1410 Upper limit

PM1404 End hose up PM1411 Lower limit

PM1405 End hose down PM1412 Preferred position for arm 1

PM1406 Unfold the placing boom PM1413 Preferred position for arm 4

PM1406A Unfold the placing boom (USA) PM1414 Preferred position arm1 + arm4

BP14_004_0501EN G13
 Glossary

G–2.10 Ergonic Boom Control, 5–arm

PM1501 Move end hose PM1507 Fold the placing boom

PM1502 End hose forwards PM1507A Fold the placing boom (USA)

PM1502A End hose forwards (USA) PM1508 End hose to the left

PM1503 End hose back PM1509 End hose to the right

PM1503A End hose back (USA) PM1510 Upper limit

PM1504 End hose up PM1511 Lower limit

PM1505 End hose down PM1512 Preferred position for arm 1

PM1506 Unfold the placing boom PM1513 Preferred position for arm 5

PM1506A Unfold the placing boom (USA) PM1514 Preferred position arm1 + arm5

G–2.11 Ergonic Boom Control, 6–arm

PM1601 Move end hose PM1607 Fold the placing boom

PM1602 End hose forwards PM1608 End hose to the left

PM1603 End hose back PM1609 End hose to the right

PM1604 End hose up PM1610 End hose back

PM1605 End hose down PM1611 End hose forwards

PM1606 Unfold the placing boom

G14 BP14_004_0501EN
 Glossary

G–3 Abbreviations and technical terms

ADR Arbeitsdrehzahlregelung#→ Speed of rotation regulation

Agitator safety cutout The agitator safety cutout automatically cuts power to the agitator
and the concrete pump when the grille is opened.

APP → Automatic Piston Pull

Arc configuration Variant of boom movement in Ergonic Boom Control mode on

machines with a Z fold system: the position of the arm assembly
resembles an arc.

Automatic Piston Pull A ball cock is fitted in the drive cylinder. When the ball cock is
closed, you can pull the delivery piston out of the delivery cylinder
to replace it.

Blockage Blockage in the delivery line: the concrete behind the blockage
cannot continue to flow. The blockage may occur due to wedging
caused by coarse particles, etc.

Change−over Reversal of direction of the delivery piston in the middle of a stroke

movement: The → transfer tube switches over. The concrete is still
pumped without interruption.

Change−over delay throttle The change−over delay throttle is a hydraulic component which
delays the change−over of the → transfer tube.

Check book The check book is part of the documentation accompanying the
machine: checklist with confirmation of the legally required checks
for concrete pumps and placing booms

Corner bearing load The corner bearing load is the force transferred to the ground
through each support foot.

BP14_002_0501EN G15
 Glossary

dB Decibels: unit of measurement for the → sound power level

dB (A) Decibels (A): unit of measurement for the → sound pressure level

EBC → Ergonic Boom Control

EDC → Electronic Diesel Control

EGD → Ergonic Graphic Display

EGD−RC → Ergonic Graphic Display  Remote Control

Electronic Diesel Control Automatic vehicle−specific control of fuel consumption

EOC → Ergonic Output Control

EPS → Ergonic Pump System

Ergonicr Registered brand name for all Putzmeister components which

control concrete pumps and placing booms.

Ergonic Boom Control Microprocessor supported system for controlling and regulating
the placing boom. Among other functions, EBC allows you to move
the placing boom using just one joystick.

Ergonic Graphic Display Graphic display in the control cabinet door. The operating state of
the machine is shown in the display. You may also be able to set
functions here, depending on the equipment on your machine.

Ergonic Graphic Display  Graphic display in the remote control. The operating state of the
Remote Control machine is shown in the display. You may also be able to set
functions here, depending on the equipment on your machine.

Ergonic Output Control Microprocessor supported system for economic operation of

theconcrete pump. The minimum engine speed required for
thedelivery rate selected by the operator is automatically set.

Ergonic Pump System Microprocessor supported system for controlling and regulating
the concrete pump. Among other functions, EPS allows you to
restrict the concrete pressure and delivery rate.

G16 BP14_002_0501EN
 Glossary

FFH → Free−Flow Hydraulics

Free−Flow Hydraulics Free−Flow Hydraulics is a type of drive for the concrete pump
which switches the fluid flow from the main pump directly to the
drive cylinders, i.e. there is free fluid flow without interposed
valves.

Fully hydraulic control Fully hydraulic control is a type of control of the concrete pump
which switches the fluid flow from the main pump to the drive
cylinder using valves (closed hydraulic circuit).

Functional fluids Hydraulic fluid, fuel, brake fluid, battery acid etc.

Grille The grille is the protective cover for the hopper and has two
functions:
− Allowing only particles up to a certain size to pass
− Protecting persons against reaching into the hopper

KEP Kolben−Endlagen−Positionierung → Piston end−of−travel

positioning

Lela → Levelled last arm

Level control Level control controls the amount of concrete in the hopper during
pumping operations using a fill−level sensor.

Levelled last arm Last arm of the placing boom in a horizontal position

BP14_002_0501EN G17
 Glossary

Machine card The machine card is part of the documentation accompanying

themachine:
− List of machine components
− Circuit diagram information

Maintenance card A maintenance card describes measures and their sequence for
maintaining the machine and for replacing parts and wear parts.

Monoblock The monoblock is a hydraulic safety valve on the boom hydraulic

cylinders.

NA / NMV NA and NMV are types of power take−off:

− The NA power take−off is a transmission−dependent PTO.
− The NMV power take−off is independent of the clutch.

One−Side−Support One−Side−Support is a type of support for supporting the machine

in narrow spaces.

Operating equipment Battery, filters

OSS → One−Side−Support

PEDOC → Putzmeister Electronic Documentation

Piston end−of−travel positioning A ball valve is fitted in the drive cylinder. When the ball valve is
closed, you can lock the drive cylinder in its end−of−travel position
to replace it.

Piston side

Proportional control Infinitely variable controller for setting the boom speed

Putzmeister Electronic Documentation accompanying the machine on CD−ROM

Documentation

G18 BP14_002_0501EN
 Glossary

Quick disconnect point Arm 1 of the arm assembly can be disconnected at the quick
disconnect point.

Reversal The concrete is sucked back from the delivery line into the hopper.

Rod side

Roll−and−fold system Type of folding of the arm assembly: the arm is rolled when folded
in and out.

Roll configuration Position of the M 31 arm assembly in Ergonic Boom Control

operation when the end hose is moved within the stored limits.

Rotor pump The rotor pump comprises

− a rotor housing
− a rotor (rotating about its central axis)
− two pressure rollers (running freely)
− a pump tube
The pump tube is pressed together as the pressure rollers roll
overit. This pushes the concrete in the pump tube ahead of
thepressure roller towards the rotor housing outlet and into the
delivery line.

RSA Rührwerksicherheitsabschaltung → Agitator safety cutout

BP14_002_0501EN G19
 Glossary

Service operation The Pumping operations − Service operations" toggle switch

onthe control cabinet can be used to switch over between the
concrete pump and the compressor. You can switch on the
compressor, rather than the pump, at the radio remote control if
you set the switch to Compressor".

Snaplock The snaplock is a mechanical safety device to protect against

unintentional extension and retraction of the support legs.

Sound power level The sound power level is a relative measurement used in acous

tics to indicate the noise emissions from a noise source[dB].

Sound pressure level The sound pressure level is a logarithmic measurement for the
relative loudness of the sound [dB(A)].

Speed of rotation regulation The ADR function regulates the mixer drum speed while the truck
is being driven.

Squeeze valve The squeeze valve is a component on the end hose which closes
the delivery line when the pump is stopped.

Stroke correction The stroke is corrected automatically by the addition or removal of

hydraulic fluid through bores in the cylinder. This means that the
delivery piston can achieve its maximum stroke length. Without
stroke correction, the delivery piston would not always reach its
end position.

Support foot The support foot is a component on the end of the support leg.

Support leg The support leg is a telescopic and/or slewable component for
supporting the machine.

Support foot plate The support foot plate is a component on the underside of the
support foot.

G20 BP14_002_0501EN
 Glossary

Teach−in Specialist word for storing in memory

Test reading The test reading is part of the documentation accompanying the
machine: list of machine setting values

to trigger The magnetic switches are triggered, i.e. when an object is

brought near, they switch without any contact being made.

Transfer tube The transfer tube is a component which is swung between the two
delivery cylinders in the hopper. It is the connection between the
delivery cylinder and the delivery line.

UVD Umsteuer−Verzögerungsdrossel → Change−over delay throttle

VHS Vollhydraulische Steuerung → Fully hydraulic control

Z fold system Type of folding of the arm assembly: the arm assembly resembles
the letter Z when folded in and out.

Z configuration Variant of boom movement in Ergonic Boom Control mode on

machines with a Z fold system: the position of the arm assembly
resembles the letter Z.

BP14_002_0501EN G21
 Glossary

G22 BP14_002_0501EN