43Z Pump

Operating Instruction
for machine operator and maintenance staff
keep by the machine
Truck--mounted
concrete pump BSF43Z.16H
Machine no. 210602351
Part Number
A820196-0704
Deutsch- Putzmeister AG +49--7127--599--0 PMW@pmw.de
land Max--Eyth--Strasse 10
PM D-- 72631 Aichtal +49--7127--599--520 www.putzmeister.de
España Putzmeister Ibérica S.A. +34--91--428 81 00 recepcion@putzmeister.es

PME Camino de Hormigueras 173
E-- 28031 Madrid +34--91--428 81 06 www.putzmeister.es
France Putzmeister France +33--169 39 69 39 Infopmf@putzmeister.fr

PMF Z.I. Rue Jean Jaurès
B.P. 81, Epinay sous Sénart +33--160 47 20 68 www.putzmeister.fr
F-- 91801 Brunoy
Italia Putzmeister Italia S.r.l. +39--0541--85 15 11 putzmeister@putzmeister.it
PMI Via Marconi, 2
I-- 47032 San Clemente (RN) +39--0541--98 98 59 www.putzmeister.it
Great Putzmeister Limited +44--1246--2642 00 info@putzmeister.co.uk

Britain Carrwood Road
PMUK GB--Chesterfield +44--1246--26 00 77 www.putzmeister.co.uk
Derbyshire S41 9QB
Turkiye TATMAK A.S. +90--212 322 12 00 rgonen@tatmak.com
TATMAK Göktürk Beldesi Istanbul Cad, No. 8/A
TR 34990 Kemerburgaz -- Eyüp +90--212 322 12 45 www.tatmak.com
Istanbul
USA Putzmeister America +1--262--886--3200 pmr@putzam.com
PMA 1733 90th Street
Sturtevant, WI 53177 USA +1--262--886--3212 www.putzmeister.com
South Putzmeister S.A. (Pty) Ltd. +27--11--794--37 90 pmsa@icon.co.za

Africa Cnr. Bramm & Citrus St. Honeydew
PMSA P.O.Box 5146 ZA 2118 Cresta +27--11--794--41 19 www.putzmeister.co.za
South Africa
India Aquarius Engineers Pvt. Ltd. +91 – 20 – 5445227 aqua@pn2.vsnl.net.in
PPI „Aquarius House“
Plot No. 65, S.No.297, Erandawane, +91 – 20 -- 5445228 www.putzpumps.biz
411 038 Pune, India
Japan Putzmeister Japan Co. Ltd. +81--489--84--1950 pmjapan@pm--j.co.jp
PMJ 70--1, Nakai Yoshikawa--shi, Saitama
342--0015 Tokyo, Japan +81--489--84--1955 www.putzmeister.de/pmj
Korea Putzmeister Korea Co. Ltd. +82--2--569--7201 pmk@putzmeister.co.kr

PMK 1287--1, Chungwang--Dong
Shihwa Ind. 3 da 502 ho, +82--2--569--7230 www.putzmeister.co.Kr
Shihung--city Kyonggi--Do, Korea
P.R.China Putzmeister Machinery Shanghai Co. Ltd +86--21--5774 1000 pmshangh@pu-
PMS 39 Dongjing Road blic.sta.net.cn
Songjiang Industrial Zone +86--21--5774 2779 www.putzmeister.com.cn
201613 Shanghai, P.R.China
Russland Hotel ”Wolga”, Apprt. No.4--174 +7--095--929--60--40, info@putzmeister.ru
PMR Bolschaja Spasskajs Str. 4
107078 Moskau, Russia +7--095--929--60--43 www.putzmeister.ru
Table of contents
1 Guide to the Operating Instructions 1–1

1.1 Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
1.2 Icons and Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
2 Safety Regulations . . . . . . . . . . . . . . . 2–1

2.1 Personnel Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2
2.2 Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2
2.3 Unfolding the Placing Boom . . . . . . . . . . . . . . . . . . . . . . . . . 2–4
2.4 Bad Weather and Storms . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4
2.5 Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5
2.6 Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5
2.7 Extending the Reach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–6
2.8 Signaller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–7
2.9 Boom Movements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–7

2.9.1 Danger Zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–8
2.9.2 High−Voltage Power Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–9
2.9.3 Static Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–9
2.9.4 Obstacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–10
2.9.5 Impermissible Working Range . . . . . . . . . . . . . . . . . . . . . . . . . 2–11
A820196_TOC_0704 I
Table of contents
3 General Technical Description . . . . 31

3.1 43Z Overview Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 2
3.2 Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 5
3.3 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 8
3.4 Machine Rating Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 8
3.5 Boom Rating Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 9
3.6 Boom and Deck Delivery/Adapter Pipe Rating Plate . . . 3 — 10
3.7 43Z Range Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 11
3.8 Description of the Functions . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 12

3.8.1 Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
3.8.2 Delivery Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
3.8.3 Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
3.8.4 Hydraulic Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
3.8.5 Concrete Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
3.8.6 S −Transfer Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
3.9 Symbols for the Control System . . . . . . . . . . . . . . . . . . . . . . 3 — 14

3.9.1 Concrete Pump (Part 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
3.9.2 Concrete Pump (Part 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
3.9.3 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
3.9.4 Electrical System (Part 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
3.9.5 Electrical System (Part 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
3.9.6 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
3.9.7 Outriggers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
3.9.8 Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
3.10 Electrical Control Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 21

3.10.1 12V/24V Converter Control Cabinet . . . . . . . . . . . . . . . . . . . . . 322
3.10.2 Central Module Control Cabinet . . . . . . . . . . . . . . . . . . . . . . . . 323
3.10.3 Door Module Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
3.10.4 OSS equipment door module . . . . . . . . . . . . . . . . . . . . . . . . . . 331
3.10.5 Control Panel in the Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
3.10.6 Cable Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
3.10.7 Radio Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
3.10.8 Radio Remote Control EBC (if equipped) . . . . . . . . . . . . . . . . 339
3.10.9 EMERGENCY SHUT−DOWN Button . . . . . . . . . . . . . . . . . . . . 345
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Table of contents
3.10.10 Proximity Switch Junction Box . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 48

3.10.11 Proximity Switch Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 50
3.10.12 Hopper Grate Cutout Device . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 51
3.11 Hydraulic Control Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 53

3.11.1 Outrigger control block operation . . . . . . . . . . . . . . . . . . . . . . 3 — 54
3.11.2 Outrigger Control Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 55
Left Outrigger Control Block . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 55
Right Outrigger Control Block . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 56
3.11.3 Boom functions control block . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 57
3.12 Mixer Control Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 58

Mixer Control Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 58
3.12.1 Agitator Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 58
Agitator Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 58
3.12.2 Water Pump Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 59
3.12.3 Agitator Shut--Off Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 60
3.12.4 Emergency operation of the agitator and water pumps . . . 3 — 61
3.12.5 Accumulator Dump Valve, Accumulator Dump Cock,
Transfer Tube Damping Cock . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 62
3.12.6 Manual Volume Control (emergency operation) . . . . . . . . . . 3 — 64
3.12.7 Hydraulic Fluid Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 65
3.13 Central Gauge Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 66
3.14 Other Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 68

3.14.1 Leveling bubble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 69
3.14.2 Water Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 70
3.14.3 Flushing Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 71
3.14.4 End hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 72
3.14.5 End Hose Weight Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 74
3.14.6 Aircuff/Squeeze Valve (If equipped) . . . . . . . . . . . . . . . . . . . . 3 — 75
3.14.7 Vibrator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 79
3.14.8 Water tank heater (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . 3 — 80
3.15 Outrigger (Swing Leg) Water Tank . . . . . . . . . . . . . . . . . . . . 3 — 82

3.15.1 Water tank connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 82
3.16 Outrigger (Swing Leg) Diesel Fuel Transfer Tank

Fuel and Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 84
3.17 Hydraulic oil tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 86
A820196_TOC_0704 III
Table of contents
4 Travel . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1
4.1 Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2
4.1.1 Prior to Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2
4.1.2 Driving in Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–3
4.1.3 During the Journey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–3
4.2 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–4
4.3 Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–8
5 Operation . . . . . . . . . . . . . . . . . . . . . . . 5–1
5.1 Preliminary Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2
5.2 Function Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2

5.2.1 Pump Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2
Switchover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2
Proximity Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3
Stroke Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3
Stroke Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3
5.2.2 Filter Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4
Vacuum Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4
Boom Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4
5.2.3 EMERGENCY SHUT−DOWN Function . . . . . . . . . . . . . . . . . . . 5–5
EMERGENCY SHUT−DOWN Button . . . . . . . . . . . . . . . . . . . . 5–6
5.2.4 Function Check on the Boom Control Unit . . . . . . . . . . . . . . . 5–6
5.2.5 Function check on the agitator safety cutout . . . . . . . . . . . . . 5–7
5.2.6 Engaging the power take−offs . . . . . . . . . . . . . . . . . . . . . . . . . 5–8
5.3 Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–11

5.3.1 Pre−Operation Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–11
5.3.2 Space Requirement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–13
5.3.3 Preliminary Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–14
Calculation Example 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–16
Calculation Example 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–16
Corner Bearing Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–21
Support Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–22
Length of the Timber Blocks Required . . . . . . . . . . . . . . . . . . 5–23
5.3.4 Remote Control Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–26
IV A820196_TOC_0704
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Radio remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–29

Boom speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–31
Restarting the pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–32
5.3.5 Outriggers Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–33
5.3.6 Danger Zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–35
5.3.7 Extending Front Support Legs . . . . . . . . . . . . . . . . . . . . . . . . . 5–36
Extending left front support leg . . . . . . . . . . . . . . . . . . . . . . . . 5–36
Extending right front support leg . . . . . . . . . . . . . . . . . . . . . . . 5–37
5.3.8 Swing Out (extend) Rear Support Legs . . . . . . . . . . . . . . . . . 5–38
Swinging out (extending) left rear support leg . . . . . . . . . . . . 5–38
Swinging out (extending) right rear support leg . . . . . . . . . . 5–39
5.3.9 Lower Front Support Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–40
Lowering left front support pad . . . . . . . . . . . . . . . . . . . . . . . . 5–40
Lowering right front support pad . . . . . . . . . . . . . . . . . . . . . . . 5–41
5.3.10 Lower Rear Support Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–42
Lowering left rear support pad . . . . . . . . . . . . . . . . . . . . . . . . . 5–42
Lowering right rear support pad . . . . . . . . . . . . . . . . . . . . . . . . 5–43
5.4 Special Case of “One - Side - Support” . . . . . . . . . . . . . . . . . 5–45

5.4.1 Supporting the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–46
5.4.2 Restricted working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–49
5.5 Boom Movements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–50

Prohibited Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–50
Overlapping Working Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . 5–50
5.5.1 Restrictions on Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–51
Bad Weather and Storms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–51
Cold Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–51
5.5.2 Signal of Boom Movements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–52
5.5.3 Temperature−Related Cylinder Movements . . . . . . . . . . . . . . 5–52
5.5.4 Uncontrolled Boom Movements . . . . . . . . . . . . . . . . . . . . . . . . 5–53
Countermeasures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–53
5.6 Hand Signals for Boom and Pumping Operations . . . . . . 5–54
5.7 Unfolding the 5 RZ Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–55

5.7.1 Unfolding sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–56
5.7.2 Impermissible working range . . . . . . . . . . . . . . . . . . . . . . . . . . 5–62
A820196_TOC_0704 V
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5.8 Unfolding the Boom when using

One - Side - Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–63
5.9 Pumping Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–69

5.9.1 Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–69
5.9.2 Notes on Correct Pumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–71
5.9.3 Starting Pumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–73
5.9.4 Pumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–74
5.9.5 Pumping in Econo−Geart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–76
5.9.6 Possible Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–77
Blockages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–77
Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–77
Restarting After Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . 5–79
5.9.7 Special Cases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–79
Continuation DeliveryLine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–79
5.10 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–81
5.10.1 Preparations for Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–81
5.10.2 Delivery Line Cleaning Methods . . . . . . . . . . . . . . . . . . . . . . . . 5–87
5.10.3 Delivery Line Suction Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 5–89
5.10.4 Cleaning the Hopper, Delivery Cylinder, and S−Tube . . . . . . 5–93
5.10.5 Truck Superstructure and Post−Washing Operations . . . . . . 5–96
5.11 Teardown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–97
5.11.1 Boom folding sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–97
5.12 Folding Sequence when using
One −Side−Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–101
5.12.1 Outriggers Teardown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–105
5.12.2 Controls Teardown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–107
5.13 Pumping Concrete With the Emergency Stroke Kit . . . . . . . . 5–108
6 Maintenance . . . . . . . . . . . . . . . . . . . . 6–1
Lock Out Tag Out Procedure . . . . . . . . . . . . . . . . . . . . . . . . 6–2
6.1 Maintenance Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3
6.2 General Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5

6.2.1 Flared Screwed Joint, Reassembly . . . . . . . . . . . . . . . . . . . . . 6–7
6.2.2 Profiled Ring Joint, Reassembly . . . . . . . . . . . . . . . . . . . . . . . . 6–7
6.3 Functional Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–8

6.3.1 Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–8
VI A820196_TOC_0704
Table of contents
6.3.2 Oil for the Power Take −Off (PTO), Rotor and
Agitator Gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–9
6.3.3 Manual Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–9
6.3.4 Centralized Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . 6–9
6.3.5 Truck Engine Oil and Transmission Oil . . . . . . . . . . . . . . . . . . 6–9
6.3.6 Level of Contaminant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–9
6.3.7 Lubricant Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–9
6.3.8 Storage of Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–9
6.4 Recommended Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–10

6.4.1 Hydraulic Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–11
6.4.2 Oils and Greases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–12
Maintenance cards
6.5 Visual Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 15
6.6 Slewing Gear Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 17

Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 619
Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 619
6.7 Changing the Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . 6–21
6.8 Function Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–27
6.9 Performing Maintenance on the Accumulator . . . . . . . . . 6–29

6.9.1 Checking Accumulator Pre−Charge Pressure . . . . . . . . . . . . 6–32
6.9.2 Decreasing Accumulator Pressure . . . . . . . . . . . . . . . . . . . . . 6–33
6.9.3 Increasing Accumulator Pressure . . . . . . . . . . . . . . . . . . . . . . 6–34
6.9.4 Replacing Accumulator Bladder . . . . . . . . . . . . . . . . . . . . . . . 6–35
6.9.5 Bladder kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–35
6.10 Hose Inspection and Replacement . . . . . . . . . . . . . . . . . . . 6 — 37
6.11 Vacuum Meter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 41
6.12 Changing the Suction Filter Element . . . . . . . . . . . . . . . . . . 6 — 43

Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 645
6.13 Changing the Pressure Filter Element . . . . . . . . . . . . . . . . 6 — 49

Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 651
Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 652
A820196_TOC_0704 VII
Table of contents
6.14 Changing the Ventilation Filter Element . . . . . . . . . . . . . . . 6 — 55
6.15 Delivery Piston Replacement 2 - KEP System . . . . . . . . . . 6 — 59

Closing the stroke correction lines . . . . . . . . . . . . . . . . . . . 660
Opening the stroke correction lines . . . . . . . . . . . . . . . . . . 666
6.16 Lubricating the S - Transfer Tube . . . . . . . . . . . . . . . . . . . . . . 6 — 67
6.17 S - Transfer Tube Replacement . . . . . . . . . . . . . . . . . . . . . . . 6–69

S−transfer tube variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–70
6.18 Measuring the Wall Thickness

(Machines with S - transfer tube) . . . . . . . . . . . . . . . . . . . . . . 6 — 89
6.19 Lubricating the Placing Boom

(M43/47 RZ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 95
6.20 Lubricating the Boom Pedestal (TRDI 140) . . . . . . . . . . . . 6 — 97
6.21 Checking the Connecting Bolts On

the Ball - Bearing Slewing Ring . . . . . . . . . . . . . . . . . . . . . . . 6 — 99
6.22 Outrigger (Swing Leg) Diesel Fuel Transfer Tank

Fuel and Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 6–101
6.22.1 Draining the Fuel Tank and Changing the fuel
filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–102
6.22.2 Refilling the Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–104
6.23 Cleaning the Outrigger (Swing Leg) Water Tank . . . . . . . 6–105
6.24 Centralized Lubrication System . . . . . . . . . . . . . . . . . . . . . . 6–113

6.24.1 Filling the lubricant reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–113
6.24.2 Fault display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–114
6.24.3 Rectifying the fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–115
6.24.4 Additional lubrication procedure . . . . . . . . . . . . . . . . . . . . . . . 6–116
6.25 Replacing the Delivery Line . . . . . . . . . . . . . . . . . . . . . . . . . . 6–117
VIII A820196_TOC_0704
Table of contents
7 Troubleshooting Guide . . . . . . . . . . . 7–1

7.1 Concrete Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–2
7.2 Placing Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–8
7.3 Boom Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–9
7.4 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–9
Appendix A: ACPA Safety Bulletin

A Setting Outriggers to Prevent Accidents . A1
Appendix B:
B EBC Operating Instructions . . . . . . . . . . . . B11
Appendix C: Index . . . . . . . . . . . . . . . . . . . C11
A820196_TOC_0704 IX
Table of contents
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X A820196_TOC_0704
1 Guide to the Operating Instructions
1.1 Foreword These Operating Instructions are intended to familiarize the user
with the machine and to assist them 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 downtimes, and to increase the reliability and
service life of the machine.
The Operating Instructions are to be supplemented by the

respective state, local, and national rules and regulations for
accident prevention and environmental 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,
such as:
• Operation, including setting up, troubleshooting in the course
of work, or tearing down the machine
• Service (maintenance, inspection, repair)
• Transport
In addition to the Operating Instructions and mandatory rules

and regulations for accident prevention and environmental
protection in the country and place of use of the machine, the
generally recognized rules of technology for safe and proper
working must also be observed.
A820196_01_0704 1–1
Guide to the Operating Instructions
Should you have any questions following your study of the

Operating Instructions, the Putzmeister Customer Support
Group, or Dealer serving you, 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 serial number.
In the interest 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.
All product descriptions, illustrations and specifications were in

effect at the time the manual was released for printing.
Putzmeister reserves the right to make changes in design or to
make additions to or improvements in its products without
imposing any obligations upon itself to install them on products
previously manufactured.
The contents of this publication may not be reproduced, even in

extract, without our written permission. All technical data,
drawings, etc. are protected by copyright.
E copyright Putzmeister PMA 2007
1–2 A820196_01_0704
1.2 Icons and symbols The following icons and symbols are used in the Operating In-
structions:
" Task symbol

Text following this symbol describes tasks which you are re-
quired to work through, generally from top to bottom in the se-
quence shown.
å Text following this symbol describes the result or effect of an

action.
Refer also to the maintenance cards:

This symbol is used to refer to the maintenance cards required,
possibly as a supplement to the maintenance card you are cur-
rently 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 information regarding environmental protection is
introduced by the icon shown, the words Environmental protec-
tion 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 ma-
chine is introduced with the icon illustrated, the word Note
printed in bold, and a line. The associated text is printed in italics
and ends with another line.
Caution
Particular information or rules or prohibitions intended to prevent
equipment damage or minor personal injury are introduced with
the icon illustrated, the word Caution printed in bold, and a line.
The associated text is printed in italics and ends with another
line.
A820196_01_0704 1–3
Warning
personal injury or significant equipment damage are introduced
with the icon illustrated, the word Warning printed in bold, and a
line. The associated text is printed in italics and ends with
another line.
Danger
serious injury or imminent death are introduced with the icon il-
lustrated, the word Danger printed in bold, and a line. The asso-
ciated text is printed in italics and ends with another line.
The appropriate symbol will be used if it is possible to identify

the source of the danger precisely.
Danger of fire
This symbol is used to identify tasks for which there is a particu-
lar danger of fire.
Danger of explosion
This symbol is used to identify tasks during which there is the
danger of an explosion. The explosion may also be caused by
pressure being released suddenly.
Falling items
This symbol is used to identify tasks in which there is a danger
of injury caused by parts falling down.
Danger of crushing
This symbol is used to identify tasks during which there is the
danger of being crushed.
1–4 A820196_01_0704
Suspended load
This symbol is used to identify tasks in which suspended loads
may fall down.
High - voltage
This symbol is used to identify tasks in which there is the danger
of electrocution, possibly with lethal consequences.
Danger of burning
of burning from chemical substances which are not specifically
described.
Danger of burning
of burning from battery acid.
Danger of poisoning
of poisoning by inhalation of gases, ingestion of or contact with
substances.
A820196_01_0704 1–5
1–6 A820196_01_0704
2 Safety Regulations
Putzmeister America cannot anticipate every possible circum-
stance that might involve a potential hazard. The warnings in
this manual are therefore not all inclusive. If a procedure, tool,
device, or work method not specifically recommended by Putz-
meister is used, you must satisfy yourself that it is safe for you
and others. You should also ensure that the machine will not be
damaged or made unsafe by the procedures you choose.
Each truck-mounted concrete pump has undergone a thorough

Quality Control inspection at the factory. The design incorporates
built-in safety features, however it can be potentially dangerous
in the hands of untrained or careless operators.
Knowing the characteristics of the machine and function of the

controls is important for safe, proper operation, and use.
Becoming familiar with the controls and practices of concrete
pumping will result in efficient and smooth pumping.
A820196_02_0704 2–1
Safety Regulations
2.1 Personnel Only qualified personnel must be allowed to operate, repair, or

Qualifications troubleshoot the truck-mounted concrete pump:
• A qualified operator is one who has read and understood the
instructions in this manual and is thoroughly familiar with the
operating characteristics and limitations of the machine.
• Qualified operators must:
− Read and have a thorough understanding of the
ACPA Safety Manual.
− Know and follow all decals and operating instructions.
− Understand and obey all applicable Local and
Government statutes and regulations applying to safe
operation and use of concrete pumping machines.
− Report any damage, defects, problems, or accidents to
their supervisor immediately.
• Repair and adjustments must only be made by qualified
personnel.
• All personnel assigned to repair or troubleshoot the
truck-mounted concrete pump must be thoroughly familiar with
and understand the job they are about to do. If in doubt, use
extreme caution and obtain assistance from other
trained/qualified personnel. Problems may arise that seem
singular but may be due to several causes.
2.2 Safety Regulations All personnel operating, assembling, transporting, or maintaining

a truck-mounted concrete pump should be aware of and comply
with the following safety regulations:
• No modification is to be made to the machine without prior
written consent of the Putzmeister Technical Support or
Engineering Department.
• While operating the unit, wear personal protective equipment
(safety goggles, hard hat etc.) required by Federal, State,
local and job site regulations.
• Do not operate the unit unless it has been leveled and
stabilized.
• Do not operate a malfunctioning unit.
• Keep decals and operating instructions legible and readable.
• Make sure safety devices are in good operating condition.
• Do not clean, oil, adjust, or service unit while it is operating.
2–2 A820196_02_0704
Safety Regulations
• Use extreme caution when handling delivery system. The

truck-mounted concrete pump is capable of delivering very
high pressures. Pressure can remain in the delivery system
even after the unit is shut down.
• Never remove the hopper grate cover when the pump is in
operation. It protects against accidental contact with the
remixer shaft and other moving parts inside the hopper.
• During normal operation never enter the hopper with any part
of your body; it is a danger area and physical injury can occur,
even if the engine is stopped.
• Do not stand on the hopper grate.
• If repair or other work must be performed inside the hopper,
ensure that engine is OFF and accumulator pressure reads
zero. The system uses a hydraulic accumulator which
contains a stored charge of high pressure oil to shift the
S-tube. Stop engine, turn ignition key to OFF and wait 10 - 15
seconds until the accumulator pressure gauge reads zero.
• Since hydraulic oil systems can be dangerous, know the
circuit you are repairing. It may contain high pressure and
injury could occur. If in doubt, stop the machine and allow
sufficient time for the oil pressure to decrease to zero. Check
pressure gauges to confirm that they read zero.
• Do not open the concrete delivery system without relieving the
pressure. Normally, pressure can be relieved by reversing the
pump and pumping backwards. However, in the event of a
rock jam, reversing the pump may not relieve the pressure
under all conditions.
• When hydraulic cylinders are used to hold loads, do not
loosen fittings without mechanically supporting the load.
Loosening of fittings may result in high pressure fluid leaks
and movement of the cylinder.
• Do not fill the fuel tank while the engine is running or hot.
Avoid the possibility of spilled fuel, which may cause a fire.
• If a fuel spill occurs, do not restart the engine until all spilled
fuel has been cleaned up.
• Do not pour material into hopper without grate in place.
Operator must monitor material being dumped in hopper,
watching for unmixed or dry concrete, sticks, pieces of metal
and other foreign objects.
• If machine is to be left unattended on a job site, secure it from
unauthorized use or movement.
A820196_02_0704 2–3
Safety Regulations
• Clear area before activating outriggers.

• Ensure that a proper level is maintained in the hydraulic oil
tank. Oil level below minimum can cause hydraulic pump and
system damage.
2.3 Unfolding the Only raise the placing boom from the transport position once the
Placing Boom supports have been properly positioned and only in the
sequence described in the Operating Instructions. The correct
sequence depends on the “folding system” (roll - and - fold
system, Z - fold system etc).
2.4 Bad Weather Return the placing boom to the transport position in the event of
and Storms storms or bad weather.
- Booms with a vertical reach of 42 m or more (M 42 and larger)
may only be operated in wind speeds up to 38 mph (61 km/h,
wind force of 7).
- Booms with a vertical reach of less than 42 m may only be
operated in wind speeds up to 46 mph (74 km/h, wind force of
8).
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 struc-
tural elements. There is a risk of lightning strike in a thunder-
storm.
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 windspeed 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.
Rule of thumb If whole trees are in motion or if effort is required to walk against
the wind, it is too windy to safely operate the placing boom and it
should be placed in the transport position!
2–4 A820196_02_0704
Safety Regulations
2.5 Driving Never drive with the placing boom in the unfolded position, the
truck might tip over.
12000100
Never drive the truck with the boom unfolded.
2.6 Loads The placing boom must never be used as lifting equipment
(crane) for lifting loads.
22000600
The placing boom must never be used for lifting loads.
A820196_02_0704 2–5
Safety Regulations
2.7 Extending the Reach It is prohibited to attach an extension (eg freely suspended
crossbeam) to the end hose or boom tip in order to extend the
reach or to pump “round the corner”, so to speak. Since the
boom and the lifting equipment for the extension have differing
pivotal points and modes of control, it is not possible to
coordinate their movements.
Impermissible extensions always place a load on the boom and

result in irreparable damage, as forces which the boom is not
designed to withstand are conducted into it. At worst, the boom
may break or the machine could topple over.
If, for reasons related to the site layout, pumping must be carried
out over greater reaches or in inaccessible places, it must be
performed in accordance with the Operating Instructions and a
separate delivery line must be laid.
A820196_02_0704 0
2–6 A820196_02_0704
Safety Regulations
2.8 Signaller Always ask the site management to supply you with an assistant
to act as a signaller and observer. Agree clear hand signals or
other signals with the signaller/observer so that you can
communicate with each other. A signaller or observer is
particularly important for you if you are operating the placing
boom with a remote control unit.
You should, therefore, position the signaller/observer 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.
2.9 Boom Movements Only slew the placing boom over persons when the end hose is
empty. There is a danger from falling concrete.
Injuries to the head and shoulder can be caused by concrete

falling out of the end hose when the placing boom is slewed over
the construction site at a great height (even when the pump is
switched off).
Injuries to workers may result from unintentional operation of the

boom control and thus unintended movement of the boom.
Press the EMERGENCY SHUT - DOWN button immediately if

the boom executes unexpected movements. You intended, for
instance, to execute the SLEW function and the boom instead
executes a different function you had not selected. The cause for
this may be an electrical fault (sticking relay or moisture in the
plug - in contacts) or sticking gates in the valves. In these cases,
you must cease working and have the precise cause of the fault
rectified by your workshop personnel or our After Sales
Department.
A820196_02_0704 2–7
Safety Regulations
2.9.1 Danger Zone
22000500
The danger zone when working with the boom is the

zone over which the boom is slewed.
2–8 A820196_02_0704
Safety Regulations
2.9.2 High - Voltage Power You MUST avoid hazardous proximity or contact with
Lines electrical power lines at all times! A minimum safety distance
of 17 feet (5 meters) must be maintained between electrical
power lines and any portion of the boom and/or truck
components at all times. The safety distance must always be
maintained when entering or exiting a job site, during
set - up and clean - up, and during the pour.
Danger
The use of a spotter is strongly recommended when
working near power lines.
MINIMUM 17 FEET DISTANCE!

(5 METERS)
A820196_02_0704 1
Always maintain the safety distance
IMPORTANT: For further safety rules in the vicinity of power lines, see the ACPA
Safety Manual discussion under “On the Job Site; Safety Rules for Job Setup.”
2.9.3 Static Charging Faults can be caused in the radio remote control system and
dangerous electrical charging of the machine can occur when
working in the vicinity of transmitters (radio transmitter etc).
Persons who bridge the charged parts to the earth are heavily
charged on contact.
A820196_02_0704 2–9
Safety Regulations
Machines in use in the vicinity of transmitters must be earthed.

Fasten the earthing strap to a bright metal point on the machine
and anchor it in the ground with an electrically conducting metal
rod.
2.9.4 Obstacles Maintain safe distances from obstacles (booms, scaffolding, etc)
without fail.
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 distance between the placing boom
and obstacles or overhead cables. Directly beneath the placing
boom there is a danger of parts of the delivery line falling.
Beneath the end hose there is a danger of falling concrete.
Avoid excessive force. The following actions (examples) will

overload the placing boom and will lead to damage and
jeopardize persons:
- lifting and transporting loads;
- pushing with the placing boom, in order to move an obstacle
out of the way, for instance;
- allowing the placing boom to strike an obstacle;
- tearing away a trapped end hose by force.
12000300
Lifting and transporting loads is forbidden.
2–10 A820196_02_0704
Safety Regulations
12000200
Striking the placing boom against obstacles is forbidden.
2.9.5 Impermissible Placing booms having boom hinges which allow considerable
Working Range flex angles, have a very large useful working range. Because of
this high mobility, various placing booms can, however, also be
shifted into positions that are of no interest for the job in hand.
Under certain circumstances it is even possible to overload or
cause damage to the placing boom. We have indicated such
unacceptable working ranges by the use of warning plates on
the machine and appropriate notes in the Operating Instructions.
22201001
1 Range in which work with the end hose is not permitted
A820196_02_0704 2–11
Safety Regulations
2–12 A820196_02_0704
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.
A820196_03_0704 3—1
General Technical Description
3.1 43Z Overview Diagram
Left truck side
3 4 5 6 7
2 8
1
24
23
22
21
20 19 18 17 16 15 14 13 12 11 10 9
A820196_03_0704 1
43Z Overview Diagram Left (Driver) Side View
No. 0 Component Page

1 Slewing gear box assembly
Boom rating plate 3--9
2
Boom and deck delivery/adapter pipe rating plate 3--10
Toolbox left side
3 12/24 volt converter box (inside toolbox) 3--22
Boom control block (inside toolbox) 3--55
4 Suction filter (behind toolbox) 3--86
Water tank (185 Gal./700L) 3--70
5
Water tank drain valve 3--72
6 Flushing water pump (on top of water tank) 3--71
7 Water tank heater (if equipped) 3--80
8 End hose (on the boom tip) [5 in. x 10 ft. (125mm x 3m)] 3--72
9 Transfer tube 3--13
10 Quick--connect for wash out gun
11 Mini step assembly
3—2 A820196_03_0704

12 Water box 3--13
13 Proximity switch junction box (on the compact block) 3--46
14 Outrigger pads
15 Storage box
Left rear outrigger (swing leg) with water tank and lid 3--82
16
Drain valve 3--82
17 Fuse box
18 Machine rating plate 3--8
Directional control block (outriggers--left side) E--stop button, and
19 3--53
leveling bubble
20 Spot lights tool box (LHS)
21 Left front outrigger
22 Pneumatic valve for pusher axle
23 Radio and/or cable remote control 3--36
24 Documentation accompanying the product
Right truck side
1 2 3 4 5 6 7 8 9 10 11
22 21 20 19 18 17 16 15 14 13 12
A820196_03_0704 2
43Z Overview Diagram Right (Passenger) Side View
A820196_03_0704 3—3

1 Hydraulic control--FFH (Free--Flow Hydraulics) 3--64
Accumulator 3--62
2
Accumulator dump valve and transfer tube damping cock 3--62
3 Central lubrication system 3--34
4 Accumulator pressure (250 bar) and high pressure (400 bar) gauges
5 Radio reciever (mounted on oil cooler) 3--40
6 Oil--air cooler (24V) double 3--64
7 O/R swing leg diesel fuel level indicator 3--84
8 Hydraulic fluid level indicator
Central module control cabinet (inside right hand toolbox) 3--23
9 Optional equipment door modules (if equipped) 3--29
OSS (One--Side--Support) door module 3--31
10 Central gauge port 3--66
11 Right front outrigger
12 Spot lights
13 Directional control block (outriggers--right side), E--stop button, 3--54
14 Leveling bubble 3--69
15 Drain valve for hydraulic fluid tank 3--86
16 Diesel fuel tank (chassis)
17 Diesel fuel transfer tank hose, nozzle and water particle filter 3--84
18 Outrigger pads
Outrigger (swing leg) diesel fuel transfer tank 3--84
19
Diesel fuel tank cap 3--84
20 Control panel (in the steps) 3--33
21 Control block mixer 3--60
22 Vibrator on the grille 3--79
3—4 A820196_03_0704
3.2 Safety Equipment This illustration shows examples of safety equipment which may
be fitted on the machine. The mounting location may differ on
different machine models (e.g. other side of the truck)
Left truck side
1
2 3 4 5 6 2 7
A820196_03_0704 3
Safety Equipment Left (Driver) Side
No. 0 Safety equipment

1 EMERGENCY SHUT--DOWN button / STOP button on the remote control
2 Snaplock on the support leg
3 OSS Beacon light
4 EMERGENCY SHUT--DOWN button
5 Two--hand control device for the support legs
6 Water box cover
7 Cover over the switch cylinders
8 End hose retaining strap
A820196_03_0704 3—5
Rear of truck
1 5
3
4
A820196_03_0704 4
Safety Equipment Rear of Truck

1 Securing cotter pins on the delivery line couplings
Folding splash guard
2 Hook catch and holder
Traction spring
3 Grille on the hopper
4 Hand rail and mini steps
5 Three lamp (red) bar
3—6 A820196_03_0704
Right truck side
1 2 3 4 5 6 7 8 9 10
A820196_03_07045
Safety Equipment Right (Passenger) Side

1 Agitator safety cutout
2 Mushroom--head button for horn on the boom
3 Grill safety mechanism
EMERGENCY SHUT--DOWN button on the control panel in the steps
4
Snaplock on the support leg (right rear swing leg)
5 Boom retaining strap
EMERGENCY SHUT--DOWN button
6
Two--hand control device for the support legs
7 Toggle switch for Local control -- 0 -- Remote control
8 OSS Beacon light
9 Snaplock on the support leg (right front outrigger)
10 Fire extinguisher (inside truck cab)
A820196_03_0704 3—7
3.3 Technical Data The technical data and settings for your machine are located on
the machine card and the pump and boom test reading sheets
with the most important data also provided on data plates
attached to the machine and boom.
3.4 Machine Rating Plate The following rating plate is attached to the machine:
1
2
3 6
4 7
5 8
A820196_03_0704 6
Machine Rating Plate

1 Model (machine model)
2 Serial No. (machine serial number)
3 Model year
4 Hydr. press max. [bar] (maximum fluid pressure in the hydraulic system)
5 Gear/Max. RPM (maximum engine speed for pumping concrete)
6 GVW rating [lbs] (permitted gross weight)
7 Concrete press. [bar] (maximum delivery pressure)
8 Gear/Max. RPM (maximum engine speed for pumping concrete)
38 A820196_03_0704
3.5 Boom Rating Plate The boom rating plate is attached to the boom (below the boom
and deck pipe length plate).
1
2
3
4
11
5
6 12
7
8 13 16
9 14 17
15 18
10
A820196_03_0704 7
Boom Rating Plate

1 Boom model
2 Boom serial no. (machine number)
3 PN of arm assembly (arm assembly part number)
4 Model year (year of manufacture)
5 Horizontal reach max. (maximum horizontal reach) [m]
6 Vertical reach max. (maximum vertical reach) [m]
7 End hose length max. (maximum end hose length) [m]
8 Max. hydr. pressure (maximum hydraulic fluid pressure) [bar]
9 Max. concrete pressure in delivery line (bar)
10 Max. weight of clamps (Lbs.)
11 Pipe (maximum permitted pipe diameter and wall thickness of the delivery
line) [mm]
12 Max. allowable bulk density of concrete to be pumped (lb/cu.ft)
13 Max. wt. of straight pipe WITH CONCRETE (Lb/ft)
14 Max. wt. of 90 degree elbow WITH CONCRETE (Lbs)
15 Max. wt. of end hose WITH CONCRETE (Lbs)
16 Max. wt. of straight pipe WITHOUT CONCRETE (Lb/ft)
17 Max. wt. of 90 degree elbow WITHOUT CONCRETE (Lbs)
18 Max. wt. of end hose WITHOUT CONCRETE (Lbs)
A820196_03_0704 3—9
3.6 Boom and Deck The boom and deck delivery/adapter pipe rating plate is
Delivery/Adapter Pipe attached to the boom (above boom rating plate) on the right
Rating Plate hand (passenger) side. For more information, please refer to the
Boom and Deck Pipe Spare Pages included with this manual.
Dia. Nom.
Putzmeister Inc.
Racine Operation
1733 90th Street L1 mm V1 mm
Sturtevant, WI 53177
L1.1 mm V2 mm
L2 mm V3 mm
L2.1 mm V4 mm
L3 mm V5 mm
L3.1 mm V6 mm
L4 mm V7 mm
L4.1 mm V8 mm
L5 mm V9 mm
L5.1 mm V10 mm
See spare parts pages 25.0 and 25.3 for details A800001 Rev. B
A820196_03_0704 8
Boom and Deck Pipe Length and Diameter Plate

1 L = Deck pipes
2 V = Boom pipes
3 Deck pipe number and length (mm)
4 Deck pipe diameter (mm)
5 Boom pipe diameter (mm)
6 Boom pipe number and length (mm)
3 — 10 A820196_03_0704
3.7 43Z Range Diagram
Outrigger Spread
Standard
With One--Side--Support
A820196_03_0704 9
Height & Reach Distance Feet (Meters)

Vertical reach 138 ft. 5 in. (42.19 m)
Horizontal reach 125 ft. 4 in. (38.20 m)
Reach from front of truck (Mack chassis) 115 ft. 7 in. (35.23 m)
Reach depth 95 ft. 6 in. (29.11 m)
Unfolding height 30 ft. 2 in. (9.20 m)
A820196_03_0704 3 — 11
3.8 Description of This section is intended to help you understand the functions of
the Functions the machine so that you can restrict the field of the machine’s
applications to suitable areas and avoid errors in operation.
3.8.1 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 very flexible movement.
3.8.2 Delivery Line The delivery and riser lines comprise standard straight pipe
sections and elbows. These are thus easily replaced. Clamp
couplings serve as both pivot joints and pipe connectors. The
elbow pivot at the end of the boom acts as a brake on the falling
concrete and reduces the wear on the end hose.
3.8.3 Outriggers The telescopic-style front outriggers and swing-out rear

outriggers, which provide the required stability, are fitted with
fully hydraulic support cylinders.
3.8.4 Hydraulic Control All boom movements are effected hydraulically. All boom
cylinders have two integral safety valves to provide protection
against overloading or rupture of the hydraulic lines. The
hydraulic fluid supply is sufficient to operate a number of
cylinders simultaneously. The hydraulic control can be operated
from the concrete pump or by using a portable remote control
unit.
The control valves are actuated:

- electrically; or
- electro - hydraulically.
The hydraulic fluid tank is integrated in the boom pedestal.

Compressed air and control current are taken from the truck.
312 A820196_03_0704
3.8.5 Concrete Pump Putzmeister concrete pumps are driven hydraulically by diesel
engine powered fluid pumps. The delivery pistons (4) are
hydraulically linked together through the driving cylinders (5).
They operate in a push--pull mode. The returning delivery piston
sucks the concrete in. At the same time, the advancing delivery
piston forces the concrete sucked in previously into the delivery
line through the pressure pipe or the pressure elbow (1). The
pump switches over at the end of the stroke. The transfer tube
(2) swings over to the full delivery cylinder (3) and the delivery
pistons (4) reverse their direction of movement.
Reverse stroke
Reversal of the delivery pistons’ (4) movement in the middle of
the stroke movement. The transfer tube (2) does not switch. The
concrete is sucked back from the delivery line into the hopper.
Switchover
Reversal of the delivery pistons’ (4) direction in the middle of the
stroke movement. The transfer tube (2) switches over. The
concrete is still pumped without interruption. Switching over
helps prevent the formation of blockages.
3.8.6 S --Transfer Tube
6 7 8
9
3
2
1
A820196_03_0704 10
Flatpack Assembly
1 Pressure elbow
2 S--Transfer tube
3 Delivery cylinder
4 Delivery piston
5 Drive cylinder
6 Water box
7 Hopper
A820196_03_0704 3 — 13
8 Switch lever
9 Agitator
3.9 Symbols for the This section gives you a summary of the symbols used for
Control System control actions.
3.9.1 Concrete Pump (Part 1)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15
A820196_03_0704 11
No 0 Designation
1 Pump in general
2 Rotor pump in general
3 Pump stand by
4 Pump On/Off
5 Pump on
6 Pump off
7 Reverse pumping
8 Stroke change--over
9 Increase -- reduce pumping rate (using rotary
controller)
10 Increase -- reduce pumping rate (using toggle switch)
11 Increase output
12 Reduce output
13 Hare = fast
14 Snail = slow
15 Cleaning
3 — 14 A820196_03_0704
3.9.2 Concrete Pump (Part 2)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
17
A820196_03_0704 12
No 0 Designation
1 Agitator in general
2 Agitator clockwise rotation
3 Agitator counterclockwise rotation
4 Agitator safety cutout
5 Level control
6 Hopper full
7 Hopper empty
8 Water tank heating
9 Mixer in general
10 Mixer mix or fill
11 Mixer drain
12 Vibrator in general
13 Vibrator On
14 Vibrator Off
15 Water pump auxiliary unit
16 Water pump
17 Compressor
A820196_03_0704 3 — 15
3.9.3 Engine
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
17 18 19
A820196_03_0704 13
No 0 Designation
1 Truck in general
2 Power take--off
3 Ignition monitoring
4 Diesel engine on
5 Diesel engine off
6 Charge monitor
7 Engine oil pressure
8 Silent (low noise)
9 Engine speed in general
10 Engine speed
11 Increase engine speed
12 Reduce engine speed
13 Tank monitoring
14 ECO (reduced fuel consumption)
15 Engine oil temperature
16 Coolant temperature
17 Coolant level
18 Engine fault (V--belt failure)
19 Air filter
3 — 16 A820196_03_0704
3.9.4 Electrical System (Part 1)
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
A820196_03_0704 14
No 0 Designation
1 Electrical system power
2 Electrical system Auto--Manual
3 On -- Off
4 On
5 OFF
6 Activate EMERGENCY SHUT--DOWN
7 EMERGENCY SHUT--DOWN activated
8 Operating hours meter
9 Operating position (local control)
10 Remote control in general
11 Radio remote control system
12 Plug in remote control
13 Cable drum
14 Fault in general
15 Acknowledge fault
16 Battery
A820196_03_0704 3 — 17
3.9.5 Electrical System (Part 2)
1 2 3 4 5 6 7 8
9 10 11
A820196_03_0704 15
No 0 Designation
1 Horn
2 Lighting in general
3 Working light
4 All--round flashing warning light
5 Analogue adjustment
6 Level control
7 Electric motor
8 Timer relay
9 Fuse
10 Fuse test
11 Test operation
3 — 18 A820196_03_0704
3.9.6 Hydraulic System
1 2 3 4 5
A820196_03_0704 16
No 0 Designation
1 Hydraulic fluid temperature
2 Cooling fan
3 Close isolating gate valve (closed)
4 Open isolating gate valve (opened)
5 Excess pressure
3.9.7 Outriggers
1 2 3 4 5
6 7
A820196_03_0704 17
No 0 Designation
1 Support leg function
2 Swing out support leg
3 Swing in support leg
4 Extend support leg
5 Retract support leg
6 Extend support foot
7 Retract support foot
A820196_03_0704 3 — 19
3.9.8 Boom
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
A820196_03_0704 18
No 0 Designation
1 Boom in general
2 Boom functions activated
3 Slewing gear activated
4 Slew boom to the right
5 Slew boom to the left
6 Move boom
7 Do not move boom
8 Arm 1 up
9 Arm 1 down
10 Arm 2 up
11 Arm 2 down
12 Arm 3 up
13 Arm 3 down
14 Arm 4 up
15 Arm 4 down
16 Switch off arm up function
3 — 20 A820196_03_0704
3.10 Electrical Control The electrical control devices and operating elements on this
Devices machine are described on the following pages. The summary at
the start of this chapter will show you where the various control
devices are located on the machine. The symbols used on the
electrical control devices are described in one of the preceding
sections.
The electrical control devices may include the following

components, depending on the equipment on your machine.
- 12V/24V Converter control cabinet
- Central module control cabinet
- Optional door modules (if equipped)
- OSS equipment (if equipped)
- Control panel in the steps
- Centralized lubrication system
- Cable remote control
- Radio remote control system
- Junction box for proximity switches
A820196_03_0704 321
3.10.1 12V/24V Converter The 12V/24V converter control cabinet is located inside the left
Control Cabinet side toolbox (may differ depending on model) and is illustrated
below. The 12V/24V converter box contains two voltage
transformers, a series of relays and fuses which convert the
12 volt electrical current from truck battery to 24 volts to power
the central module control and/or any other equipment requiring
24 volts electrical power (e.g., oil cooler fans, auto lube, vibrator,
etc.).
1
2
A820196_03_0704 19
12V/24V Converter Control Cabinet

1 Voltage transformers (inside cabinet)
2 Relays (inside cabinet)
3 Electric fan (inside cabinet)
4 Key
3 — 22 A820196_03_0704
3.10.2 Central Module The central module control cabinet is illustrated below. Some of
Control Cabinet the control and operating elements illustrated below may not be
present on your machine. The hole will be covered with a
blanking plug if a control or operating element is omitted.
You will find the description of any additional door modules and
their control and operating elements fitted in place of the blank-
ing plates on the following pages.
1 2
13
3 4 5 6 7 8 9
14
11 10
12 12
15
12 12
A820196_03_0704 20
Operating/ Belongs
No 0 Meaning/Function
control element with no:
1 Red indicator lamp (optional) Coolant overheating 4
2 Red indicator lamp (optional) High - pressure water pump
dry - running cut - out
3 Toggle switch Hydraulic fluid radiator On - Off
4 Toggle switch (optional) Coolant overheating Off 1
A820196_03_0704 323
Operating/ Belongs
5 Toggle switch (optional) Pumping operation - Service op-
eration
6 Toggle switch (optional) Working light On - Off
9 Locally latched toggle switch Local control - 0 - Remote control
10 Multiple plug with protecting Connection for diagnostic system
cap
11 Multiple display Display
12 Blanking plate Options for door modules
13 Key Unlocks cabinet door
14 Bag for documentation Circuit diagrams
15 Female connector with cap Connection for remote control
Multiple Display
1 2
3 4 5 6 7
A820196_03_0704 21
Multiple Display Window on Control Cabinet
Belongs with
No 0 Control element Meaning/Function
no:
1 Thermometer Hydraulic fluid temperature display
2 Operating hours meter Operating hours display
3 Green display Forward pumping On
324 A820196_03_0704
Belongs with
No 0 Control element Meaning/Function
no:
4 Green display Reverse pumping On
5 Red display Hydraulic fluid overheating /
Temperature sensor lead break
6 Red display EMERGENCY SHUT - DOWN acti-
vated
7 Green display Hydraulic fluid radiator fan On
Special Features of the Control Cabinet
Locally latched To use a toggle switch that has been latched locally, you must
toggle switches first pull it out and then push it towards the symbol.
Locking The control cabinet may be found in a stowage compartment.

You must always lock this stowage compartment to prevent any
unauthorized person switching the control system over.
Switchover from local to The EMERGENCY SHUT - DOWN circuit is activated automati-
remote control cally when you switch over from local to remote control. You
must operate the horn to deactivate the EMERGENCY SHUT -
DOWN circuit.
Coolant overheating The “Coolant overheating” indicator lamp is connected to the ve-
hicle’s warning system. In the event of an engine fault, the ma-
chine is switched to EMERGENCY SHUT - DOWN and the en-
gine is shut down. Once you have eliminated the fault, you must
press the “Coolant overheating Off” toggle switch before you can
restart the engine. You can override the shut - down by holding
down the “Coolant overheating Off” toggle switch in order to op-
erate the machine for a short time (eg to pump out the hopper
and delivery line).
Pumping operation - Ser- Use the “Pumping operation - Service operation” toggle switch
vice operation to switch over between the concrete pump and the compressor.
You can switch on the compressor, rather than the pump, at the
remote control if you set the switch to “Compressor”.
Note
As soon as the compressor is switched on, the agitator control
block is no longer supplied with hydraulic fluid, ie the agitator
and the water pump will not run.
A820196_03_0704 325
Diagnostics socket To capture data from the machine, a diagnostics unit can be
connected to the diagnostics socket by authorised and qualified
personnel.
Stroke correction Electronic stroke correction on this machine takes place as

required.
Note
You can obtain further information from the “Proximity Switch
Junction Box” section of this chapter.
Hydraulic fluid tempera- The hydraulic fluid temperature is measured at the main hydrau-
ture display in the multi- lic pump. The left - hand green LED flashes if the hydraulic fluid
ple display temperature is below approximately 149_F (65_C) at this point.
The left - hand LED of the two red LEDs lights up if the hydraulic
fluid temperature exceeds 194_F (90_C). The red “Hydraulic
fluid overheating” display lights up at the same time. The two red
LEDs flash alternately if the hydraulic fluid temperature exceeds
approximately 203_F (95_C).
Operating hours display The operating hours meter is activated when the pump is
in the multiple display switched on. The flashing egg - timer symbol in the display indi-
cates that the meter is active.
Status displays in the mul- These displays indicate the machine’s statuses. The two red dis-
tiple display plays indicate the following:
- “EMERGENCY SHUT - DOWN activated” symbol lights up:
EMERGENCY SHUT - DOWN activated
- “Hydraulic fluid overheating” symbol lights up: The hydraulic
fluid is too hot. The red LEDs in the temperature display light
up or flash depending on the temperature.
- “Hydraulic fluid overheating” symbol flashing: The temperature
sensor on the main hydraulic pump is defective or there is a
break in the cable. The two red LEDs in the temperature dis-
play flash alternately and the hydraulic fluid radiator fan be-
gins to run at the same time (one fan runs where there are two
hydraulic fluid radiators).
326 A820196_03_0704
Caution
In the event of a fault or a line break to the temperature sensor
on the main hydraulic pump, the switch - off temperature 194_F
(90_C) for the hydraulic fluid is no longer monitored. This means
that the machine will not be switched off should the hydraulic
fluid overheat.
Switch the machine off and replace the temperature sensor if the
“Hydraulic fluid overheating” display flashes.
3.10.3 Door Module Options Door modules on the central module control cabinet can include
optional Ergonic Output Control (EOC), optional accessories, or
One - Side - Support (OSS) standard equipment as illustrated.
Door module - The Ergonic Output Control (EOC) door module option on the
Ergonic Output central module control cabinet is illustrated below. Some of the
Control control and operating elements illustrated below may not be
(if equipped) present on your machine. The hole will be filled with a blanking
plug if a control or operating element is omitted.
Note
Ergonic Output Control (EOC) is electronically controlled output
regulation which adapts the engine speed to the delivery rate
selected. It is recommended that you switch off EOC control in
arduous pump conditions (e. g. high - density concrete).
A820196_03_0704 22
Ergonic Output Control Module
A820196_03_0704 327
Special features of Ergonic Output Control
Engaging the The engine speed remains at 850 rpm after the power take - off is
power take-off engaged.
Boom or support leg The engine speed is increased to 1350 rpm as soon as you op-
function erate a boom or support leg function with the concrete pump
switched off.
Pump On As soon as you switch on the concrete pump, the engine speed
is increased to a level appropriate for the delivery rate set on the
output regulation rotary controller, but to no less than 1350 rpm.
Output Engine speed

> 75% 1350 rpm − maximum engine
speed
0 − 75% 1350 rpm
0% 850 rpm (after 10 seconds)
If the output is set to more than 75%, the engine speed is in-
creased until the computed engine speed is reached (the maxi-
mum being the upper engine speed limit).
If the output is set to less than 75%, the engine speed is held
at 1350 rpm. The control pressure for the hydraulic pump is then
modified automatically.
Pump Off, or no boom The engine speed is reduced to 850 rpm after 10 seconds
movement (works setting), if you:
- reduce the output to 0% or
- switch the concrete pump off, or
- no longer control a boom function when the concrete pump is
switched off.
Should you switch the concrete pump back on or operate a
boom function inside this 10 second delay, the engine speed is
maintained.
Adjusting the engine If you change the engine speed manually from the remote con-
speed manually trol, this manually set engine speed is maintained until you:
- adjust the output at the rotary controller again,
- disengage the power take - off,
- switch off the ignition.
328 A820196_03_0704
Water pump and other As previously described, the engine speed is reduced after
auxiliary units 10 seconds when the concrete pump is switched off. You must
increase the engine speed manually in order to operate the
water pump or other auxiliary units. Once you have manually
increased the engine speed, this remains increased until you
move the boom again or switch on the concrete pump. The
10 second countdown then begins again.
Additional door Additional door module options on the central module control
module options cabinet is illustrated below. Some of the control and operating
(if equipped) elements illustrated below may not be present on your machine.
The hole will be filled with a blanking plug if a control or
operating element is omitted.
1 2 3 4
A820196_03_0704 23
Door Module Options
Operating/ Belongs
No. 0 Meaning/Function
control element with no.:
1 Toggle switch ECO operation
2 Locally latched toggle switch Support leg warning lights On - Off
3 Locally latched toggle switch Squeeze valve On - Off
4 Toggle switch Level control On - Off
A820196_03_0704 329
Locally latched To use a locally latched toggle switch, you must first pull it out
toggle switches and then push it towards the symbol.
Special features of the door module
ECO operation The “ECO operation” toggle switch is used to limit the maximum
speed of the engine.
Switch position Maximum possible engine speed

up 1200
centre maximum engine speed
down 1350
Often, you do not need to use the maximum possible pump

output on construction sites. If you limit the maximum speed of
the engine and also, therefore, the pump output, then
- less fuel is consumed,
- the environment is polluted less,
- noise emission levels are reduced,
- and the concrete is pumped more smoothly.
Support leg warning lights You can use this toggle switch to switch the support leg warning
lights on and off. The ignition must be switched on and the
power take - off must be engaged for this switch to be used.
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.
Level control The hopper contains two sensors which you can trigger with the
“Level control” toggle switch. When level control is active, the
pump will only switch on once the concrete in the hopper has
reached the upper sensor. The pump switches itself off
automatically if the fill level of the concrete in the hopper drops
below the lower sensor.
330 A820196_03_0704
3.10.4 OSS equipment door The Door Module for the OSS equipment is illustrated below.
module This equipment allows the machine to be set up in a narrow
space. The flashing beacons for the working range are attached
to the top of the boom pedestal at the front (left and right side of
truck), or on top of tool box. The beacon light will illuminate
automatically when the OSS key switch is turned on for one or
both sides and can be manually turned off using the beacon light
switch on the door module.
Warning
The outrigger support legs on the SELECTED OSS side
MUST BE FULLY SWUNG OUT, FULLY EXTENDED, AND
LOWERED. The outrigger support legs on the restricted
side must be lowered in the fully retracted position (since
intermediated positions are not permitted).
Caution
The OSS key - switch must be set to the desired position
(Right OSS or Left OSS) and the key removed (to prevent
anyone from changing the position) BEFORE UNFOLDING
THE BOOM.
1
2
A820196_03_0704 24
1 Limit Switch 2. OSS Beacon Light
A820196_03_0704 331
When the OSS is activated (left or right side) the limit switches installed on the boom
slewing head (as shown) will limit boom slewing operation to 120 degrees.
A820196_03_0704 25
One - Side - Support (OSS) Door Module
Operating/
control element
1 Green indicator lamp Left OSS working range selected
2 Keyswitch Select OSS working range (Left OSS, No OSS,
Right OSS)
3 Green indicator lamp Right OSS working range selected
4 Toggle switch Cancel OSS working range
Switch off OSS flashing beacon
332 A820196_03_0704
3.10.5 Control Panel The control panel is located in or near the steps on right hand
in the Steps side of truck. The truck mixer driver can control the most
important functions of the pump from the control panel. In
addition, it provides an opportunity for local operation of the
machine. Some of the control and operating elements illustrated
below may not be present on your machine. The hole will be
covered with a blanking plug if a control or operating element is
omitted.
9 2 3 4 5 7 A820196_03_0704 26
Operating/
control element
1 Momentary - contact switch EMERGENCY SHUT - DOWN
2 Toggle switch Horn + deactivate EMERGENCY SHUT - DOWN /
Pump Off
3 Toggle switch Vibrator On - Off
4 Toggle switch Forward pumping - 0 - Reverse pumping
5 Toggle switch Increase - Reduce engine speed
6 Toggle switch Centralized lubrication system
7 Green indicator lamp Boom centralized lubrication system
8 Green indicator lamp Pump centralized lubrication system
9 Red indicator lamp EMERGENCY SHUT - DOWN
A820196_03_0704 333
Special Features of the Control Panel
Restart pump after If you have pressed the EMERGENCY SHUT - DOWN button,
EMERGENCY SHUT- you may only start the pump up again as described below:
DOWN - unlock the EMERGENCY SHUT - DOWN button by turning it,
- press the “Horn + deactivate EMERGENCY SHUT - DOWN”
toggle switch,
- switch the pump off and then on again using the “Forward
pumping - 0 - Reverse pumping” toggle switch.
Forward pumping - 0 - The function of the “Forward pumping - 0 - Reverse pumping”

Reverse pumping toggle switch depends on the switch position of the Local - Re-
mote switch on the control cabinet.
- When the toggle switch is set to “Local”, it has the functions
given above.
- When the switch is set to “Remote”, it is only possible to
switch the pump off using the “Pump off” toggle switch.
Centralized lubrication The centralized lubrication system for this machine is described
system on the following pages.
Note
If your machine is equipped with pump centralized lubrication
system, the pump centralized lubrication system and the boom
centralized lubrication system are two completely independent
systems, that is two pumps, two lubricant reservoirs, two
controllers, etc. The toggle switch can then be pressed in either
direction and it will address the system selected.
334 A820196_03_0704
Technical data Rated voltage (V DC) 12 / 24
Operating voltage (V DC) 10 ... 30
Off-load current at 12 V (mA) 15
Off-load current at 24 V (mA) 18
Motor current (A) 6
Lamp current (A) 2
Ambient temperature (°C) -40 ... +80
Inputs secure against polarity reversal
secure against polarity reversal/

Outputs
short-circuit protected
Relative operating period (%) 100
Degree of protection fitted in the

IP 6 K 9 K DIN 40050 T9
pump casing
Indicator lamps The indicator lamps illuminate when lubrication is in progress

(i.e., the lube pump is turned on).
A820196_03_0704 27
A820196_03_0704 335
Flash interval Meaning
2 seconds on, then off Self-test after pump switched on

1 second on, 1 second off Fault in the drive motor or supply line
½ second on, ½ second off Lubricant reservoir empty
½ second on, 1 second off Fault in the lubrication circuit

Lubrication in progress
Steady light A fault which was previously indicated has been
acknowledged (see “toggle switch”)
Programming Various settings are programmed into the centralized lubrication

system in the works. These settings regulate the lubrication in-
tervals and the lubrication time. Have the default settings modi-
fied by the After Sales Department if either the lubrication inter-
vals or the lubrication times do not meet your needs. The
following settings are stored:
Interval time The interval time is the time between two lubrication procedures.
The interval time only runs down when the ignition is switched
on. The interval times are retained during interruptions. The new
times are added on restarting.
Working time The working time is the time for which the centralized lubrication
pump operates for one lubrication procedure. The working time
is the period during which a response must be received from the
piston detectors.
Monitoring time The monitoring time starts when the centralized lubrication pump
is switched on. The monitoring time is the time taken for the pis-
ton detector to respond.
336 A820196_03_0704
3.10.6 Cable Remote Control The standard cable remote control for this machine is illustrated
below.
11
2
12
10 3 4
9
5
6
8
7 A820196_03_0704 28
Operating/ Belongs
1 Joystick Boom control
2 Toggle switch Cable remote ON/OFF 3
3 Green indicator lamp Cable remote ON 2
5 Toggle switch Horn + deactivate EMERGENCY SHUT-DOWN /
Change - over
6 Rotary controller Increase - Reduce output
7 Toggle switch Boom speed preselection:
Hare = 100%
Snail = 0 - 100%
8 Toggle switch Engine On - Off
10 Locally latched toggle Boom functions - 0 - Support leg control
switch
11 Red indicator lamp Fault (eg EMERGENCY SHUT - DOWN oper- 12
ated)
12 Momentary - contact switch EMERGENCY SHUT - DOWN 11
A820196_03_0704 337
Special features of the cable remote control
Restart pump after The red “Fault” indicator lamp lights up when the EMERGENCY
EMERGENCY SHUT- SHUT - DOWN button is pressed. You may only start the pump
DOWN up again as described below:
- unlock the EMERGENCY SHUT - DOWN button by turning it,
toggle switch,
3.10.7 Radio Remote Control The transmitter for a radio remote control is described below.
ÁÁÁ
11
1
ÁÁÁ ÁÁ
ÁÁÁ ÁÁ
10
2
9
ÁÁÁ 3
Á
12 13
ÁÁÁ
8
4
ÁÁÁ
7 ÁÁÁ 5
6
A820196_03_0704 29
Operating/ Belongs
2 Toggle switch Radio remote control unit On - Off 12
4 Toggle switch Horn + deactivate EMERGENCY SHUT -
DOWN / Change - over
338 A820196_03_0704
Operating/ Belongs
6 Locally latched toggle switch Preselect boom speed:
Snail = 50% of the works setting -
10
User - defined speed -
Hare = 100% of the works setting
7 Toggle switch Engine On - Off
9 Locally latched toggle switch Boom functions - 0 - Support leg control
10 Toggle switch Program user - defined boom speed 7
11 Momentary - contact switch STOP function
12 Green indicator lamp Flashing: remote control unit in service 2
Off: no contact with receiver
13 Red indicator lamp Flashing: battery flat
3.10.8 Radio Remote Control You can control the machine with or without the EBC (Ergonic
EBC (if equipped) Boom Control) functions using the radio remote control. You will
see below how you must connect the individual control
components to permit control of the machine without EBC
functions.
10 1
9
ÁÁ
ÁÁ
2
3
Á
8
11 12
4
7
5
6 A820196_03_0704 30
A820196_03_0704 339
Operating/ Belongs
2 Toggle switch Radio remote control unit On - Off 11
4 Toggle switch Horn + deactivate EMERGENCY SHUT -
DOWN / Change - over
6 Locally latched toggle switch Preselect boom speed:
Snail = 50% of the works setting -
9
User - defined speed -
Hare = 100% of the works setting
7 Selector switch Control boom arms, move end hose,
semi - automatic operation, programming 1
operation
8 Locally latched toggle switch Boom functions - 0 - Support leg control
9 Toggle switch Storing and deleting 6
10 Momentary - contact switch STOP function
11 Green indicator lamp Flashing: remote control unit in service 2
Off: no contact with receiver
12 Red indicator lamp Flashing: battery flat
Note
The radio remote control EBC functions are described in
separate Operating Instructions which can be found along with
these Operating Instructions.
The boom control block receives the control signals either from
the central control cabinet or the EBC control cabinet, depending
on where the connector to the boom control block is plugged in.
You must plug the boom control block connector into the central
control cabinet female connector to control the machine without
EBC functions.
340 A820196_03_0704
2
10
3 8
7 9
4
A820196_03_0704 31
No 0 Designation
1 Central control cabinet
2 EBC control cabinet
3 Radio remote control receiver
4 Radio remote control transmitter
5 Cable remote control
6 Connector to boom control block
7 Female connector from the EBC control cabinet
(EBC operation)
8 Female connector from the central control cabinet
(operation without EBC)
9 Boom control block
Female connector to the central control cabinet for input
10
signals from the radio or cable remote control
A820196_03_0704 341
Receiver
5 7
2
6
4
A820196_03_0704 32
Operating/ Belongs
1 Antenna Signal reception
2 ReceiverAntenna with base Converts signals to control command-
sControl signal reception
3 Indicator lamps Operating states display
4 Female connector Connection to the control cabinet
5 Female connector Antenna connection
6 Antenna with base Control signal reception
7 Battery compartment Charge battery
Charge state of battery (Battery charger located in truck cab)
Red indicator lamp The red indicator lamp lights up when the battery is defective.
Yellow indicator lamp The yellow indicator lamp lights up to indicate that the battery is
charging.
Green indicator lamp The green indicator lamp lights up when the battery is fully
charged.
342 A820196_03_0704
Special features of the radio remote control
STOP button Putzmeister radio remote controls include a STOP button having
the same function as the EMERGENCY SHUT - DOWN buttons
on the machine.
Restart pump after STOP You may only start the pump up again as described below if you
have pressed the STOP button:
- unlock the STOP button by turning it,
- switch remote control unit off and back on again,
toggle switch,
Frequency change 12 frequencies on the frequency band have been assigned to

this radio remote control. As soon as you switch the transmitter
off or press the STOP button on the transmitter, the link between
the transmitter and receiver is broken. The radio remote control
automatically advances to the next frequency when you switch
the transmitter back on.
Additional antennae You must maintain a minimum clearance of 1 m between the ra-
dio remote control antenna and any additional antennae (eg ra-
dio, telephone) you fit, as otherwise these may interfere with the
radio remote control.
Joystick The two joysticks can be used to control the individual boom
functions. You can control some of the boom functions for 4 and
5 arm booms by rotating the joysticks.
A820196_03_0704 343
Preselect boom speed You can select different speeds of movement for the boom using
toggle switch the “Preselect boom speed” toggle switch.
- In the Snail position of the switch, the boom functions are
operated at 50% of the speed set in the works.
- In the middle position of the switch, the boom functions are
operated at the user - defined speeds of movement.
- In the Hare position of the switch, the boom functions are
operated at 100% of the speed set in the works.
Program user-defined You can program your own speed for each of the boom functions
boom speed toggle switch using the “Program user - defined boom speed” toggle switch.
- You program the maximum boom speeds with the toggle
switch in the upper position.
- You program the minimum boom speeds with the toggle
switch in the lower position.
Programming your own Each boom movement must be programmed individually.

boom speed
Programming a maximum speed
" Set the “Preselect boom speed” toggle switch to “User - de-
fined speed”.
" Press the “Program user - defined boom speed” toggle

switch up and hold.
" Use the joystick to control the boom movement desired at

the speed that is to become the maximum speed for full
joystick deflection.
" Release the toggle switch first and then the joystick.
344 A820196_03_0704
Programming a minimum speed
" Set the “Preselect boom speed” toggle switch to “User - de-
fined speed”.
" Press the “Program user - defined boom speed” toggle

switch down and hold.
" Use the joystick to control the boom movement desired at

the speed that is to become the minimum speed for mini-
mum joystick deflection.
" Release the toggle switch first and then the joystick.
Now when you set the “Preselect boom speed” toggle switch to
the middle position and move the joystick to its full deflection, the
boom movement will be executed at the maximum speed of
movement you have just programmed. When you now move the
joystick only slightly, the boom movement will be executed at the
minimum speed of movement you have just programmed.
Note
The electronics in the radio remote control prevent you program-
ming a minimum speed that is higher than the maximum speed.
Inhibiting individual arm If you move the joystick only very slightly so that the boom does
movements not move when you are programming the maximum speed for a
boom movement, this direction of movement will be inhibited.
3.10.9 EMERGENCY There are a number of EMERGENCY SHUT - DOWN buttons on

SHUT - DOWN Button the machine. These are located:
- by every outrigger control block
- on the cable and radio remote control boxes
- on the electric control box near the hopper
A820196_03_0704 345
Some possible positions of the EMERGENCY SHUT - DOWN

button are shown in the illustration below.
Caution
Familiarize yourself with the locations of the EMERGENCY
SHUT - DOWN buttons on your machine before operating the
unit.
A800029
ÁÁ
ÁÁ
Á A820196_03_0704 33
EMERGENCY SHUT - DOWN Button Locations
Note
You need only press one of the EMERGENCY SHUT - DOWN
buttons to trigger an EMERGENCY SHUT - DOWN of the
machine.
To release the EMERGENCY SHUT - DOWN condition again,
you must unlock the EMERGENCY SHUT - DOWN button that
has been pressed by turning it and sound the horn.
You must switch the pump off and back on again to restart the
pump. All EMERGENCY SHUT-DOWN buttons must be
released for machine operation.
346 A820196_03_0704
The following actions are triggered in the truck, pump and boom systems when you press one of the
EMERGENCY SHUT-DOWN buttons:
System Action
Truck - Engine speed drops to idle.

- It is no longer possible to set the engine speed electrically.
Pump - The “EMERGENCY SHUT - DOWN operated” indicator lamp lights on the
control cabinet.
- Variable main pumps go to neutral, the delivery pistons come to a halt, and
the “Pump On” light flashes.
- The change - over valve is de-energized.
Warning
The accumulator pump continues to generate hydraulic flow, which is directed back to
tank instead of operating the function (i.e., the accumulator ceases to be filled).
Boom - The boom control unit is disconnected.

- If the E-stop on the radio transmitter was pressed, the supply voltage to the
radio transmitter is switched off and the power indicator lamp on the radio
transmitter goes out. If an E-stop on the truck was pressed, the power
indicator lamp on the radio transmitter flashes.
- On the cable remote control system, the supply voltage is switched off with the
exception of that for the horn, the “Fault” indicator lamp on the cable remote
control unit lights, the “Pump on” light flashes.
- The boom pump transports hydraulic fluid in depressurized circulation
(maximum 15 bar) 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.
Caution
The machine is only switched off electrically when the
EMERGENCY SHUT - DOWN 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.
A820196_03_0704 347
3.10.10 Proximity Switch The junction box for the proximity switches is located next to the
Junction Box compact block on the right side (seen in the direction of travel) of
the truck.
CYL 2 For Stroke Correction

For Shifting 6
Rod Side
CYL 1
Head Side
4
3 Stroke Correction
5
4
CYL 2
1 3 5
3 6
2
CYL 1
CYL 1
Rod Side 2 4 6
1 5
20500404
A820196_03_0704 34
Assignment of Proximity Switches to LEDs
Junction Box LEDs There are four proximity switches located on cylinder one of the
core pump, two at the rod side and two at the head.side There
are also two proximity switches located on cylinder two on the rod
side. The four switches located on the rod side of both cylinder
one and two are for shifting and the two switches located at the
head side of cylinder one are for stroke correction. These
switches trigger the switchover procedure when the hydraulic
pistons approach the proximity switches. The LEDs for the two
proximity switches that have just been triggered light up on the
junction box at the same time.
348 A820196_03_0704
No. 0 Control element Proximity Switch

1 Yellow LED Cylinder 1 rod side (cylinder shift)
5 Yellow LED Cylinder 1 head side (stroke correction)
6 Yellow LED Cylinder 1 head side (stroke correction)
Significance of
Junction Box LED Proximity Switch Status
the Junction Box LEDs
Lights up briefly on switchover Proximity switch is in order
Does not light up on switchover Proximity switch, connector or

lead are defective, replace at the
earliest opportunity
Lights up continuously Proximity switch, connector or

lead are defective, disconnect the
switch (otherwise switchover is
not possible) and replace at
earliest opportunity
Note
Further LEDs are located on the Proximity switch connector (see
page 3 — 50). These LEDs indicate whether it is the Proximity
switch or the connector and lead that is defective.
Redundant system One of the two proximity switches on each end is sufficient to
trigger the switchover procedure. The second proximity switch
serves as a backup in case one of the two proximity switches
should fail. You may use one of the proximity switches from the
other end as a replacement if both the switches on one end (rod
end or base end) fail during a job.
A820196_03_0704 349
3.10.11 Proximity Switch The connector for the proximity switch has one yellow and one
Connector green light - emitting diode (LED). These LEDs indicate the
status of the connector and the proximity switch.
1 2 3
A820196_03_0704 35
Proximity Switch Connector

1 Yellow LED - Indicates the status of the proximity switch.
2 Green LED - Indicates the status of the connector and the lead.
3 Connector
4 Proximity Switch
Significance of
Yellow LED Proximity Switch Status
the Proximity Switch
LEDs Lights up briefly on switchover Proximity switch is in order
Does not light up on switch- Proximity switch is defective, replace at

over earliest opportunity
Lights up continuously Proximity switch is defective, disconnect the

switch (otherwise switchover is not possible)
and replace at earliest opportunity
Green LED Connector and Lead Status
Lights up A voltage is being applied to the connector

(i.e., connector and lead are in order)
Does not light up No voltage is being applied to the connector

(i.e., connector or lead are defective)
350 A820196_03_0704
3.10.12 Hopper Grate Cutout The hopper grate cutout device consists of a switching cam and
Device a pressure roller switch. The switching cam is fastened to the
hinge pin of the hopper grate, the pressure roller switch to the
hopper. The pressure roller switch is acted on as soon as you
open the hopper grate. This causes the agitator to halt and the
pressure to be dumped from the accumulator (i.e. the transfer
tube will no longer be able to switch over). In addition, the
delivery pistons return to the end position and the concrete
pump halts. You must switch the concrete pump off and back on
again to re - start it.
1 2 3 4
A820196_03_0704 36
Hopper Grate Cutout Device

1 Hopper
2 Hopper grate hinge pin
3 Switching cam
4 Pressure roller switch
Caution
The pressure roller switch must always be clean and free to
move. In addition, the pressure roller switch must always be in
contact with the switching cam. If the pressure roller switch is
defective, the hopper grate cutout device may not function, or
the agitator and the transfer tube may come to a halt during
pumping operations.
A820196_03_0704 351
Warning
BEFORE LIFTING HOPPER GRATE TO WORK ON CONCRETE PUMP, VERIFY
THAT HOPPER GRATE CUTOUT DEVICE IS WORKING PROPERLY BY
PERFORMING THE FOLLOWING STEPS: (1) While concrete pump is ON, reach
hand beneath cutout cover and push switch up (refer to diagram below). DO NOT
ATTEMPT TO RAISE HOPPER GRATE. (2) Verify that concrete pump turns OFF.
Hopper grate cutout cover,

which is located on
passenger’s side of truck.
Position of hopper grate cutout

switch with hopper grate
CLOSED. In this position, the
concrete pump can be turned ON.
Position of hopper grate cutout

switch when hopper grate is OPEN.
In this position, the concrete pump
should automatically turn OFF.
A820196_03_0704 37
352 A820196_03_0704
3.11 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.
- Outriggers control block
- Boom functions control block
- Agitator lever
- Water pump lever
- Agitator shut - off valve
- Compact block valves (e.g., manual volume control valve,
accumulator dump valve, etc.)
- Transfer tube damping cock
- Free - flow hydraulic block and emergency operation
- Hydraulic fluid radiator
- Central gauge port
Note
Further control devices and components are described in the
“Electrical Control Devices” section and the “Other Components”
section.
A820196_03_0704 353
3.11.1 Outrigger control The outrigger control block on the left (driver’s) and right
block operation (passenger’s) side of the truck is illustrated as follows.
Special features of the support control block
Two-hand control device The outrigger control block is designed as a two - hand control
device, i.e. to execute a function, you must operate the preselect
lever and the corresponding function lever simultaneously.
Spring-loaded The hydraulic support valves are spring - loaded, i.e. the valves
are automatically reset to zero position when you release the
levers.
Direction of operation
A820196_03_0704 38
Contorl Block Operation
The lever must be moved up and down or forwards and

backwards to execute the support functions depending on the
installation position of the control block or operating lever.
354 A820196_03_0704
3.11.2 Outrigger Control The outriggers control block on the left (driver’s) and right
Block (passenger’s) side of the truck are illustrated below.
Left Outrigger Control

Block
A800031
2 3 4 5
A820196_03_0704 39
Outrigger Control Block (located on driver’s side)

1 Left outrigger on/off lever - Push lever in and hold to activate the left
outrigger controls or release lever to deactivate the left outrigger controls.
2 Outrigger left front (LF) up/down - Pull lever out to raise LF outrigger or
push in to lower LF outrigger.
3 Outrigger left rear (LR) up/down - Pull lever out to raise LR outrigger or
push in to lower LR outrigger.
4 Outrigger left front (LF) out/in - Pull lever out to extend LF outrigger or
push in to retract LF outrigger.
5 Outrigger left rear (LR) out/in - Pull lever out to extend LR outrigger or
push in to retract LR outrigger.
6 EMERGENCY SHUT-DOWN button
A820196_03_0704 355
Right Outrigger Control

Block
A800029
5 4 3 2 A820196_03_0704 40
Outrigger Control Block (Located on Passenger’s Side)

1 Right outrigger on/off lever - Push lever in and hold to activate the left
outrigger controls or release lever to deactivate the left outrigger controls.
2 Outrigger right front (RF) up/down - Pull lever out to raise RF outrigger or
push in to lower RF outrigger.
3 Outrigger right rear (RR) up/down - Pull lever out to raise RR outrigger or
push in to lower RR outrigger.
4 Outrigger right front (RF) out/in - Pull lever out to extend RF outrigger or
push in to retract RF outrigger.
5 Outrigger right rear (RR) out/in - Pull lever out to extend RR outrigger or
push in to retract RR outrigger.
6 EMERGENCY SHUT-DOWN button
Note
The support control block is designed as a two - hand control
device (i.e. to execute a function, you must operate the on/off
lever and the corresponding function lever simultaneously).
The hydraulic outrigger valves are spring - loaded (i.e., the valves
are automatically reset to the “0” position when you release the
lever).
356 A820196_03_0704
3.11.3 Boom functions The control block can be operated manually and thus provides
control block security of operation if a malfunction occurs in the remote con−
trol system.
1 2 3 4 5 6 7
A820196_03_0704 41
No. 0 Designation
1 Support or boom function On − Off
2 Slew boom Clockwise − Anti−clockwise
3 Arm 1 Up − Down
4 Arm 2 Up − Down
5 Arm 3 Up − Down
6 Arm 4 Up − Down
7 Arm 5 Up − Down
Note
Depending on the mounting position, the boom functions con−
trol block operating levers may point up or down. The lever as−
signment sequence may also be from right to left or vice versa.
It may also be the case that the control block is installed rotated
through 90°. Familiarise yourself with the functions of the control
block by reading the notices affixed to it.
A820196_03_0704 357
3.12 Mixer Control Block The mixer control block with the water pump and agitator lever is
mounted on the right front corner of the hopper. Use the agitator
lever to switch on the agitator in either direction of rotation.
Mixer Control Block
4
5
A820196_03_0704 42
Mixer Control Block and Hopper Agitator

1 Agitator shut - off with lever
2 Grill safety mechanism
3 Mixer control block
4 Agitator shut - off valve
5 Hydraulic motor for agitator
3.12.1 Agitator Lever
A820196_03_0704 43
Operation of Agitator Lever
358 A820196_03_0704
1 Agitator ON (lever upwards) - Agitator direction away from the delivery

cylinder
2 Agitator OFF
3 Agitator ON (lever downwards) - Agitator direction towards the delivery
cylinder
4 Water pump lever
Note
As the two valves on the agitator control block are supplied by a
single hydraulic pump, it may be the case that the volume of
hydraulic fluid is not adequate to supply the functions of both
valves with sufficient hydraulic fluid at the same time. It can
therefore be the case that the agitator does not operate when
the water pump is switched on, or that the water pump does not
operate when the agitator is switched on.
3.12.2 Water Pump Lever The water pump lever is located next to the agitator lever on the
mixer control block.
2
Do Not Operate
Water Pump
Without 3
Water
A820196_03_0704 44
Operation of Water pump lever

1 Water pump ON
2 Water pump OFF
3 Agitator lever
A820196_03_0704 359
Note
As the two valves on the agitator control block are supplied by a
single hydraulic pump, it may be the case that the volume of
hydraulic fluid is not adequate to supply the functions of both
valves with sufficient hydraulic fluid at the same time. It can
therefore be the case that the agitator does not operate when
the water pump is switched on, or that the water pump does not
operate when the agitator is switched on.
3.12.3 Agitator Shut - Off The agitator shut - off valve is incorporated into the agitator
Valve control block. If there is no power to the agitator shut - off valve
(when the hopper is open or the EMERGENCY SHUT - DOWN
button has been pressed), hydraulic fluid does not flow to the
agitator valve (i.e., the agitator halts).
1 A820196_03_0704 45
Agitator Control Valve

1 Agitator shut-off valve
360 A820196_03_0704
3.12.4 Emergency operation You can operate the agitator and the water pumps manually from the
of the agitator and hydraulic control block illustrated below if the control panel has failed.
water pumps
A820196_03_0704 46
No. 0 Designation
1 Water pump valve
2 Agitator valve
3 Agitator safety cutout valve
Special features of the hydraulic control block
Flushing water pump You must hold the water pump valve down to operate the flushing
emergency operation water pump in emergency mode.
Note
You need only hold down the emergency operation valve for the high-
pressure water pump to run the high-pressure water pump (optional) in
emergency mode.
Agitator emergency oper- You must hold down the valve for the agitator safety cutout and the
ation agitator valve to run the agitator in emergency mode.
A820196_03_0704 361
3.12.5 Accumulator Dump This machine is fitted with an electrical agitator safety cutout.
Valve, Accumulator The accumulator pressure is dumped through an accumulator
Dump Cock, Transfer dump valve and the transfer tube halts, among other measures,
Tube Damping Cock as soon as the grill on the hopper is opened. The accumulator
dump valve is located on the left of the hydraulic block, seen in
the direction of travel.
The machine is fitted with an additional accumulator dump cock.

The accumulator pressure is also dumped when the accumulator
dump cock is opened. The transfer tube will still switch over
while the machine is running, although at a lower pressure and
very slowly. This will allow you to halt the transfer tube in the
center position by switching off the machine at the appropriate
moment. You can then check the wear ring using a mirror, for
example.
The transfer tube damping cock is incorporated in the hydraulic

fluid supply line to the accumulator.
Caution
The transfer tube will continue to switch over when the
accumulator dump cock has been opened and the machine is
running. There is still a danger of crushing and severing of limbs.
Never reach into the hopper from below through the wash - out
port nor from above through the grill while the machine is run-
ning. Never poke anything into the hopper.
362 A820196_03_0704
3 5
2
4
A820196_03_0704 47
No 0 Designation
1 Accumulator
2 Additional accumulator dump cock
3 Accumulator pressure gauge
4 Accumulator dump valve
5 Transfer tube damping cock
A820196_03_0704 363
3.12.6 Manual Volume On this machine, the output is adjusted by means of a

Control (emergency proportional valve. This proportional valve is integrated in the
operation) Free - Flow Hydraulics (FFH) control block. The handwheel
required for emergency operation is located on the forward end
of the Free - Flow Hydraulics control block (as viewed from front
of truck).
A820196_03_0704 48
No 0 Designation
1 Emergency operation handwheel
2 Free - Flow Hydraulics (FFH) control block
Note
The proportional valve must be fully open during normal opera-
tion, i.e. the emergency operation handwheel must be turned
fully counterclockwise (opened).
A fixed value of 75% is set on the proportional valve when you
switch over from remote control to local control on the control
cabinet, and the output can only be controlled by the engine
speed. This means that an output of 75% of the maximum output
is possible at maximum engine speed.
In emergency operation you are able to set the output desired on
the proportional valve using the handwheel. The further you turn
the handwheel clockwise, i.e. the further you close the propor-
tional valve, the greater the output will be.
364 A820196_03_0704
3.12.7 Hydraulic Fluid The machine is fitted with a double hydraulic oil cooler.
Radiator There are two 24 volt fans. Some of the hydraulic fluid in the
machine first flows through this cooler before returning to the
reservoir. The fans switch on once the hydraulic fluid reaches a
temperature of 131_F (55 _C) or they may be switched on
manually at the central control cabinet.
A820196_03_0704 49
Hydraulic Fluid Radiator

1 Control cabinet symbol for the hydraulic fluid radiator
2 Hydraulic fluid return circuit
3 Fans (24V)
4 Hydraulic fluid supply circuit
5 131_F (55_C) temperature sensor
A820196_03_0704 365
Note
You may switch on both fans at any time using the toggle switch
on the control cabinet, whatever the fluid temperature, should
you wish to cool the hydraulic fluid as a precautionary measure
before it has reached 131_F (55_C). The green indicator lamp
on the control cabinet will light up as soon as a temperature of
131_F (55_C) is reached, or if you have switched on the fans.
Leave the truck engine running during breaks in pumping or

when pumping is completed until the fan motors switch
themselves off.
The hydraulic fluid is also cooled by the water in the water box.
The hydraulic fluid warms up the piston rods for the drive
cylinders. These are flushed, and thus cooled, by the water in
the water box on each stroke movement. This also cools the
hydraulic fluid. The water in the waterbox should be flushed and
refilled daily.
3.13 Central Gauge Port The central gauge port is located in the right hand (passenger)
side toolbox. The central gauge port is used for hydraulic system
diagnostics. There are 11 ports with gauge couplings that can be
connected via elbow coupling and hose to either a 400 or 60 bar
gauge. When connected, the hydraulic pressure from the
hydraulic component is measured using the pressure gauge. For
more detailed information, please refer to the hydraulic pump
and boom schematic included in this manual.
Note
For more detailed information, please refer to the hydraulic
pump and boom schematic included with this manual.
366 A820196_03_0704
2 3 5 6
1 4 7 8 9 10 11
m1 m6 m4 m3 m8 m2/5 m7 m7 m2/5 m7 m7
13
12
200 30
m1 m8
20 40
100 300
m6
m2/5 10 50
m4
0 bar 400 0 bar 60
m3 m7
A820196_03_0704 50
Central gauge port (11 ports)

1 (m1) Main hydraulic pump gauge coupling and hydraulic hose connected to measuring connection on
hydraulic control FHH and hydraulic circuit for actuating pressure controller/automatic flow control/main
pump.
2 (m6) Boom control block gauge coupling with elbow fitting and hose connected to 400 bar gauge (13)
and to measuring connection on boom control block and hydraulic circuit for auxiliary pump for boom.
3 (m4) Auxiliary pump for agitator gauge coupling and hydraulic hose connected to measuring connection
on hydraulic control for agitator and hydraulic circuit for auxiliary pump for agitator.
4 (m3) Auxiliary pump for accumulator gauge coupling and hydraulic hose connected to measuring
connection on hydraulic control FHH and hydraulic circuit for auxiliary pump for accumulator.
5 (m8) Output volume regulator gauge coupling with elbow fitting and hose connected to 60 bar gauge
(12) and to measuring connection on hydraulic control FHH and hydraulic circuit for output volume
regulation (24V).
6 (m2/5) Main hydraulic pump gauge coupling and hydraulic hose connected to main hydraulic pump.
(m2) measures hydraulic pressure (30 bar) from insert pressure limiting valve on pump. (m5) measures
hydraulic pressure (34 bar) from main hydraulic pump.
7 (m7) Main hydraulic pump gauge coupling and hydraulic hose connected to main hydraulic pump with
SAE/drive unit and reversal control valve circuit.
8 (m7) Main hydraulic pump gauge coupling and hydraulic hose connected to main hydraulic pump with
SAE/drive unit and stroke change over switch control valve circuit.
9 (m2/5) Secondary hydraulic pump gauge coupling and hydraulic hose connected to secondary hydraulic
pump. (m2) measures hydraulic pressure from suction filter and drive unit circuit of secondary hydraulic
pump. (m5) measures hydraulic pressure (34 bar) from secondary hydraulic pump.
10 (m7) Secondary hydraulic pump gauge coupling and hydraulic hose connected to secondary hydraulic
pump without SAE, drive unit and reversal control valve circuit.
11 (m7) secondary hydraulic pump gauge coupling and hydraulic hose connected to secondary hydraulic
pump without SAE, drive unit and stroke change over switch control valve circuit.
A820196_03_0704 367
3.14 Other Components The other components of this machine are described on the
following pages. The summary at the start of this chapter will
show you where the various components are located on the
machine. The symbols used on the other components are
described in one of the preceding sections.
The following components may be described here, depending on

the equipment on your machine.
- Leveling bubble
- Water tank
- Flushing water pump
- End hose
- Aircuff/squeeze valve (if equipped)
- Vibrator
- Water tank heater (if equipped)
- High-pressure water pump (if equipped)
Note
Additional control devices and components are described in the
“Hydraulic Control Devices” section and the “Electrical Control
Devices” section.
368 A820196_03_0704
3.14.1 Leveling bubble A leveling bubble is fitted on both sides of the machine in the
immediate vicinity of the “support control block”. The leveling
bubble is a visual aid for setting up the machine horizontally
within the permissible tolerance.
5d
3d
A820196_03_0704 51
Caution
If the machine deviates from the horizontal by more than 3°, the
boom and the boom pedestal are excessively loaded.
Furthermore, the stability of the machine is jeopardised.
The leveling bubbles are fitted in such a way that you can easily
check that the machine is level while it is being supported. If the
leveling bubbles or their brackets are damaged, the level
position of the machine cannot be guaranteed.
For this reason, check both leveling bubbles and their brackets
for visible damage daily. Have any damage rectified immediately.
Damage has also occurred if the displays in the two leveling
bubbles differ.
Furthermore, the leveling bubbles must undergo an annual

inspection. The result of the inspection must be documented in
the check book and confirmed by the inspector.
A820196_03_0704 369
3.14.2 Water Tank The water tank assembly is located on the front left side deck
next to the outrigger. The capacity for the water tank is 185
gallons (700 Liters) and is connected to left side swing leg
auxiliary water tank. The water tank supplies water for the water
pump, water box, water tank heater (if equipped), wash--out kit,
or high pressure washer (if equpped).
3
2
9
1
A820196_03_0704 52
Water Tank Assembly

1 Water tank
2 Breather tube
3 Flushing water pump
4 Guard
5 Water level inidcator
6 Drain port
7 Port (connected to O/R water tank)
8 Clean out lid
9 Port (Water heater)
3 — 70 A820196_03_0704
3.14.3 Flushing Water Pump The flushing water pump is located on top of the water tank. The
flushing water pump generates a maximum water pressure of
368 psi (25 bar) and a maximum water delivery rate of 42
gallons per minute (160 liters per minute).
4 2
1 3
3
1
A820196_03_0704 53
Flushing Water Pump (Located on Top of Water Tank)

1 Water hose connection for cleaning port
2 Hydraulic motor
3 Flushing Water pump
4 Ball valve
5 Water tank
Note
Some of the fittings installed on the flushing water pump may or
may not be the same on your machine.
A820196_03_0704 371
3.14.4 End hose The machine is fitted with a 3 or 4 m long end hose depending
on the model. The maximum permitted end hose length is shown
on the boom weight limit decal affixed to arm 4 or 5. There are
two automatic brackets attached to the arm which automatically
catch the end hose when arm “D” or “E” (depending on model) is
unfolded in a single motion.
3
A820196_03_0704 54
End Hose Automatic Brackets

1 Arm “D” or “E” (depending on model)
2 Automatic brackets
3 End hose mounting bracket
Warning
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. The machine can tip over if you use a longer end hose.
372 A820196_03_0704
Note
End hoses may not be fitted with any extension coupling, outlet
shoes or other dangerous outlet fitting. However, you can use
the modified Putzmeister end hose with a flow restrictor if you
wish to achieve a uniform flow of concrete for filling hollow
blocks.
ÂÂÂ
ÂÂ
ÂÂ
ÂÂÂ
ÂÂ
ÂÂÂ
ÂÂ
ÂÂÂ
1
ÂÂ
ÂÂÂ
2
ÂÂ
ÂÂÂ
ÂÂ
ÂÂÂ
3
ÂÂ
ÂÂÂ
4
A820196_03_0704 55
Modified Putzmeister End Hose With a Flow Restrictor

1 Rubber protective sleeve
2 Modified end hose
3 Push-in spout
4 Flow restrictor
Warning
The modified end hose with a 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.
A820196_03_0704 373
3.14.5 End Hose Weight Limit
A820196_03_0704 56
Note
The end hose is permanently exposed to high loads and severe
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.
3
2
A820196_03_0704 57
Retaining Rope on the End Hose

1 Snap hook
2 Retaining rope
3 Push-on connection
4 Hose clamp
3 — 74 A820196_03_0704
Warning
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 otherwise the end hose would fall when the coupling was
opened.
Check the retaining rope for damage every day. A damaged re-
taining rope must be replaced by a new retaining rope immedi-
ately.
3.14.6 Aircuff/Squeeze Valve An optional aircuff/squeeze valve kit is shown below. The
(If equipped) squeeze (or “quench”) valve is used to close off the delivery line
above the end hose during brief breaks in pumping to prevent
concrete running out of the delivery line. This is particularly use-
ful in applications such as
- underwater concrete placement or
- in jobs where the concrete must be precisely “dosed”.
Caution
Total weight of all hanging hoses, reducers, and clamps
including concrete must not exceed 210 pounds. The stability of
the machine is jeopardized if this weight limit is exceeded.
A820196_03_0704 375
ARO
3 8
Max PSI 200
(13.8 Bar) 4 5
Temp 180_F
6
(62_C)
A820196_03_0704 58
Aircuff and Regulator (Optional)

1 Air solenoid valve
2 Air regulator knob
3 Air hose (out)
4 Pressure gauge (160 Bar)
5 Air valve muffler
6 Electric wire
7 Air hose (in)
8 Aircuff assembly
376 A820196_03_0704
5 6
7 7
8 8
1 2 3
A820196_03_0704 59
No 0 Designation
1 Compressed air supply shut - off valve
2 Squeeze valve control toggle switch: (a) In OFF position, squeeze valve is always
open, (b) In ON position, squeeze valve is closed and automatically opens if: (1)
Turn Pump ON (after 4 second time delay), (2) Pump in Reverse, or (3) Push in
E-Stop.
3 Toggle switch for pump On/Off at remote control
4 Delivery line bend on the last arm
5 Squeeze valve (open)
6 Squeeze valve (closed)
7 Compressed air port
8 End hose retaining rope
9 End hose
A820196_03_0704 377
Special features of the squeeze valve
The squeeze valve is supplied with compressed air from the

vehicle. A shut - off valve, which has to be opened in order to use
the squeeze valve, is installed in the compressed air supply line.
The squeeze valve can be activated at the control cabinet or at a
separate control panel. The squeeze valve will be automatically
closed as soon as you switch the pump off and will open again
when the pump is switched on. 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.The squeeze valve is also opened if
you set the pump to reverse pumping to allow cleaning.
3
1 2
A820196_03_0704 60
Operating/ Belongs
No. 0 Meaning/Function
1 Toggle switch ECO operation
2 Toggle switch Squeeze valve On - Off
3 Toggle switch Level control On - Off
378 A820196_03_0704
3.14.7 Vibrator The vibrator is bolted to the grill. It causes the grill to vibrate and
thus prevents bridges forming on the grill, particularly in the case
of very stiff concrete. The vibrator is electrically driven and its
connector must be plugged into the appropriate round socket on
the side of the electric control cabinet. The vibrator is switched
on and off either at the electric control cabinet or on the control
panel by the steps.
1
3
4
A820196_03_0704 61
Vibrator
1 Grill
2 Vibrator
3 Supply cable
4 Plug
A820196_03_0704 379
3.14.8 Water tank heater An optional water tank heater is available for the outrigger and
(if equipped) pedestal water tanks as shown in the lllustration below:
coolant OUT to
truck engine
coolant IN from
truck engine
1
3
2
4
A820196_03_0704 62
Water tank heater kit - 47M

1 Water tank (outrigger)
2 Heat exchanger
3 3/4 in. NPT connections
4 Water tank (pedestal)
5 Drain cock
380 A820196_03_0704
The water tank heater is connected via hoses to the truck engine manifold as shown in
the illustration below:
1. Valve lever ’up’ (vertical) - heater is ’Off’

OFF 2. Valve lever ’down’ (horizontal) - heater is ’On’
ON
Return to Engine Manifold Heat Exchanger
From Engine Manifold

A820196_03_0704 63
Water Tank Heater and Engine Manifold Circuit
The engine circulates warm coolant from the engine manifold through a heat exchanger
inserted in the water tank (swing leg), then back to the engine manifold. For this reason,
there are two coolant lines (outlet and return) that run from the engine manifold to the
heat exchanger. There is a manual shut off valve that is used to turn the water heater on
or off.
To turn the heater ON:

" Rotate the valve handle on ball valve to the horizontal (On) position
To turn the heater OFF:

" Rotate the valve handle on ball valve to the vertical (Off) position
Note
When the valve handle is in the ON position, the water tank heater will continue to heat
as long as the engine is running.
A820196_03_0704 381
3.15 Outrigger (Swing Leg) The left hand “driver’s” side outrigger (swing leg) has a water
Water Tank tank built in for use as an additional supply of water. The swing
leg and components used may differ depending on model (e.g.,
ball valves, caps, hoses etc.). Refer to the “Maintenance” chap-
ter for additional information on maintenance intervals and pro-
cedures.
Warning
Do not pressurize tank. Pressurizing the tank can cause serious
personal injury and/or equipment damage.
A820196_03_0704 64
Safety decal affixed to swing leg on top near water cap
3.15.1 Water tank

connections 1
4 3 2
A820196_03_0704 65
Water tank and Outrigger (Swing Leg) Auxiliary Water Tank

1 Water tank deck (185 Gal/700L)
2 Outrigger (Swing Leg) water tank
3 Drain cock
4 Pipe fittings
5 Flexible rubber hose and clamps
The swing leg water tank is connected to the water tank on the
deck on lower left hand side via flexible rubber hose and clamps.
3 — 82 A820196_03_0704
4 1 2
3
4 7
6
5
9
8
A820196_03_0704 66
Outrigger (Swing Leg) Auxiliary Water Tank (Left Side)

1 Cap
2 Water level indicator
3 Access plug
4 Clean out lid assembly
5 Clean out lid
6 Clamping cross
7 O - ring
8 Socket head cap screw
9 Gasket
A820196_03_0704 383
3.16 Outrigger (Swing The right hand “passenger” side outrigger (swing leg) has a
Leg) Diesel Fuel diesel fuel tank built in for use as an auxiliary diesel fuel supply.
Transfer Tank Fuel The tank has a ball valve that is connected to a water - particle
and Filter filter and a hose with a nozzle at the end to transfer the diesel
Replacement fuel into the truck diesel fuel tank. The tank can be filled via the
diesel fuel cap on top of tank. A level gauge is used to indicate
the amount of diesel fuel in the tank. Refer to the “Maintenance”
chapter for additional information on maintenance intervals and
procedures.
Warning
A820196_03_0704 67
Safety decal affixed to swing leg on top near fuel cap
384 A820196_03_0704
6
7
2 3 4
1
A820196_03_0704 68
Outrigger diesel fuel tank hose and nozzle

1 Fuel hose nozzle
2 Fuel hose
3 Ball valve
4 Water - particle fuel filter
5 Truck fuel tank
6 Fuel level gauge
7 Outrigger diesel fuel tank (right “passenger” side)
8 Fuel tank cap
A820196_03_0704 385
3.17 Hydraulic Oil Tank
2
4
3
1
2
7
A820196_03_0704 69
Hydraulic Oil Tank Components

1 Hydraulic oil tank (179 Gal./680L)
2 Air filter
3 Tank drain valve
4 Tank lid
5 Sieve tank filler tube
6 Diffuser (32 Gal./min [31 Gal./min. [120L/min])
7 Suction filter with 10μ filter element
The 40M class concrete pump incorporates a hydraulic tank into

the pedestal. The tank has two ventilation filters, one filler tube
with lid and particle sieve, and a suction filter with 10 micron filter
element. Inside the tank is a diffuser rated at 31 gal./min
(120L/min.) that is used as an aerator for the hydraulic oil
returning from the oil cooler.
3 — 86 A820196_03_0704
4 Travel
In this section you will find information concerning the safe

transport of the machine.
A820196_04_0704 4–1
Travel
4.1 Driving The truck-mounted concrete pump may be driven on public

highways only if the vehicle and driver are properly licensed.
4.1.1 Prior to Driving Prior to driving the truck, perform the following actions:
• Check that the vehicle is safe to drive (lighting, brakes, tire
pressures, etc.).
• Verify that the following items stored on the truck are properly
secured:
− Delivery hoses
− Delivery pipes
− Clamps
− Tools
− Outrigger pads
− Cable remote control box and cable
• Verify that the outrigger legs are secured in the transport
position.
Caution
To prevent the outriggers from accidentally extending while the
truck is moving, close the hydraulic shut - off valves in the
outrigger system and ensure that each outrigger leg snaplock is
secured by a spring pin.
• Ensure that the truck maximum allowable weight limits are not
exceeded. Also ensure that all local or state weight limits are
not exceeded.
• Check that the oil and water reservoirs are securely closed
and not leaking.
• Verify that PTO switch in truck cab is in DRIVE position. If not,
depress clutch pedal, start engine, and flip PTO switch to
DRIVE position.
• Do not drive the unit with concrete in the hopper.
• Remove all concrete delivery line components from the pump.
• Verify that the boom is in its stowed position (i.e., not
unfolded).
4–2 A820196_04_0704
Travel
4.1.2 Driving in Reverse If you have to drive in reverse, perform the following actions:
• Always ask for a marshaller to guide you.
• Agree upon clear hand signals with the marshaller before
backing up.
• If necessary, have the route blocked or secured by assistants.
• Have the site management arrange for the removal of any
materials or equipment that hinder your approach.
• Ensure that pusher axle is in raised position.
4.1.3 During the Journey Due to the size and weight of the truck, observe the following
precautions when driving:
• Keep an adequate distance from slopes and pits.
• Only drive over arches, bridges or other supporting structures
if the load-bearing capacity is adequate.
• Be aware of the height of the truck in height restricted areas
(i.e., underpasses, under bridges, etc.).
• Be aware of the elevated position of the truck’s center of
gravity when travelling on a slope and on ascending or
descending routes.
Warning
The truck may never be driven with the placing boom unfolded.
This may cause the truck to tip over.
12000100
Never drive the truck with the boom unfolded.
A820196_04_0704 4–3
Travel
4.2 Towing The truck-mounted concrete pump may only be towed in

accordance with the truck manufacturer’s rules. Use the towing
equipment provided. As shown in the diagram below, a coupling
is fitted on the front of the truck for breakdown rescue or towing
the truck:
Caution
Only use the towing eye on the rear of the truck for assistance
on the construction site if a tow-bar cannot be fitted to the front
of the truck. Never tow the truck by the pump unit or the
hopper.
A820196_04_0704 10
Tow coupling on the front of the truck
4–4 A820196_04_0704
Travel
40000204
Caution
If you wish to tow the machine from the towing eye on the rear
swinging support leg, the swinging support leg must be swung
fully in, and the direction of towing must be along the truck axis.
Serious damage may be caused to the boom pedestal, the
swinging support leg and the slewing cylinder if the swinging
support leg is swung out, or if you tow at an angle.
Make sure that the towing rope or the tow - bar does not damage
the hopper or other parts of the bodywork if you use the towing
eye near the hopper.
A820196_04_0704 4–5
Travel
10000400
Towing eye on the rear of the truck
You must use the towing eye on the rear of the truck to tow the
truck from the rear.
40000203
Towing eye
4–6 A820196_04_0704
Travel
The towing eye on machines with TRS 60 or TRS 70 boom ped-

estals is mounted over the compartment housing the rear sup-
port.
40000201
Towing eye on the support cylinder
The lifting eye on the support cylinder may be used as the tow-
ing eye on M 42 and larger machines.
40000202
Towing eye at the rear of the swinging support leg
A820196_04_0704 4–7
Travel
The towing eye on machines with TRDI 60 or TRDI 70 boom

pedestals is mounted on the rear of the swinging support leg.
4.3 Loading The standard slinging hooks fitted to the machine are there for
assembly purposes only. Slinging hooks suitable for lifting the
complete machine can be ordered on a new machine and may,
possibly, be retro - fitted to an old machine. If your machine is
fitted with suitable slinging hooks, they will be identified as
follows:
10002400
Plate for slinging hooks
Suspended load
Raised loads may fall if they are not loaded properly or if the
slings and hooks are damaged.
You should, therefore, never walk under suspended loads.
4–8 A820196_04_0704
Travel
Caution
The machine may only be loaded by crane if it is equipped with
suitable slinging hooks. Lifting equipment, lifting tackle, supports
and other auxiliary equipment shall be safe in use and operation.
Make sure that the loadbearing capacity is adequate.
10000600
Do not lift the machine by the assembly slinging points
A820196_04_0704 4–9
Travel
4–10 A820196_04_0704
5 Operation
In this chapter you will find information on the operation of

the machine. You will learn what operations are required for
commissioning, for setting up the machine, for pumping opera-
tions and for cleaning.
A820196_05_0704 5–1
Operation
5.1 Preliminary Before attempting to place material with the truck-mounted

Information concrete pump, operators must be thoroughly trained in its
operation. Before using the truck-mounted concrete pump,
complete the following steps:
• Perform routine truck maintenance as outlined in your truck
owner’s manual.
• Completely inspect the truck-mounted concrete pump for worn
or damaged parts, loose bolts, missing parts, etc.
• Perform periodic maintenance on the truck-mounted concrete
pump, as outlined in the Maintenance section of this manual.
Warning
Read and comply with all safety rules, notes, and warnings
contained in this manual. This is absolutely essential to the
safe, efficient operation of the truck-mounted concrete pump.
Note
Prior to starting up the machine, you should become so familiar
with the machine that damage and accidents cannot occur.
Every time you use the machine, you accept full responsibility for
the safety of anyone located in the machine’s danger zone. You
are therefore under an obligation to ensure that the machine is
completely safe in operation.
5.2 Function Checks You should check the following functions before you begin using
the machine on the construction site
5.2.1 Pump Functions The basic precondition for problem - free operation of the
machine is a properly functioning pump.
Switchover Check for the proper switchover function of the delivery pistons
and the transfer tube at various speeds of the drive motor and
settings of the flow regulator.
5–2 A820196_05_0704
Operation
Proximity Switch
A820196_05_0704 1
Check the Proximity Switch
Check whether the drive cylinders are switching over

automatically as soon as the pistons of drive cylinder I (on the
right in the direction of travel) approach the two forward or rear
proximity switches. The associated indicator lamp on the
distributor casing should light up briefly. If one of the indicator
lamps does not light up, the associated proximity switch is
defective.
Stroke Length Press the switchover button on the remote control at a slow
delivery piston speed and hold it down.
The delivery pistons should move to their end positions. Stroke
correction is automatic and is complete when both delivery
pistons come to a halt (may be seen in the water box).
Stroke Time Fully close manual volume control valve (by rotating
counterclockwise) to have pump operate at maximum speed.
Measure the stroke time over ten individual strokes. The value
determined, divided by 10, must comply with the ratings on the
Pump test reading sheet following the machine card in the
Technical Data section.
A820196_05_0704 5–3
Operation
5.2.2 Filter Functions Dirty filters reduce the fluid flow considerably so that damage
may occur in the hydraulic system.
Vacuum Filter
A820196_05_0704 2
Vacuum Meter - The filter element must be replaced if the vacuum meter indicator
is in the red zone at more than 85°F (30°C) fluid temperature and the fastest
stroke time.
Boom Filter
A820196_05_0704 3
Pressing Down the Red Button on the Boom Filter
1. Warm up the hydraulic fluid to normal operating temperature u

120°F (50°C).
2. Set the maximum pumping rate.
3. Press in the red button on the boom filter if it is sticking out.

Note
You must replace the boom filter element if the red button pops
out again after a short time.
The boom filter is OK if the red button remains depressed.
Comply with the waste disposal regulations in force for your area
when changing the fluid filters.
5–4 A820196_05_0704
Operation
5.2.3 EMERGENCY It is only possible to intervene rapidly in the event of danger if all
SHUT - DOWN the EMERGENCY SHUT - DOWN buttons are functioning.
Function
Caution
The machine is no longer safe in operation if the EMERGENCY
SHUT - DOWN button 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
SHUT - DOWN buttons and the lever position for the boom
valves (see “Function check on the boom control unit”) before
starting work each time.
Caution
The machine is only switched off electrically when the
EMERGENCY SHUT - DOWN 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.
Furthermore, the EMERGENCY SHUT - DOWN circuit has no

influence on the agitator pump (i.e., the agitator continues to
rotate, despite the EMERGENCY SHUT - DOWN button having
been pressed in).
A820196_05_0704 5–5
Operation
EMERGENCY
SHUT - DOWN Button
A820196_05_0704 4
Press - Lock EMERGENCY SHUT - DOWN

Turn - Unlock EMERGENCY SHUT - DOWN
1. Switch the pump on.
2. Operate a boom function.
3. Press one of the EMERGENCY SHUT - DOWN buttons.

The pump and the boom must come to a halt immediately.
4. Check all EMERGENCY SHUT - DOWN buttons on the

machine and on the remote control in the same way.
5.2.4 Function Check on the You may only operate the machine if the boom control unit is
Boom Control Unit fully functional.
1. Switch on the radio or cable control.
2. Operate the boom control levers briefly several times while

observing the levers on the boom control unit. The lever for
the boom valve operated and the lever for the operating
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 approximately 0.8 seconds if you use
the cable control or radio.
5–6 A820196_05_0704
Operation
5.2.5 Function check on the This machine is fitted with an agitator safety cutout (RSA). A
agitator safety cutout pressure roller switch is acted on as soon as you open the grille.
This causes the agitator to halt and the pressure to be dumped
from the accumulator, i. e. the transfer tube will no longer be
able to switch over. In addition, the delivery pistons return to the
end position and the concrete pump halts.
Caution
A defective agitator safety cutout can cause you to believe that
the machine is safe, even though this is not really the case. This
can lead to the agitator continuing to run or the transfer tube
switching over when the grille is open.
You must therefore check the function of the agitator safety cut-
out before you start each pumping job.
A820196_05_0704 5
" Open the grille with the concrete pump running.

⇒ The switching cam acts on the pressure roller switch.
⇒ The agitator must come to a halt immediately.
⇒ The transfer tube must no longer switch over.
⇒ The concrete pump must run to the end position and
halt.
A820196_05_0704 5–7
Operation
Warning
You must stop work if you open the grille, but
– the agitator continues to run, or
– the transfer tube continues to switch, or
– the concrete pump does not run to its end position.
Note
You must switch the concrete pump off and back on again to
re--start it.
5.2.6 Engaging the power The NMV power take--off is upstream of the gearbox and is
take--offs independent of the clutch. The NMV power take--off drives the
hydraulic pumps for the concrete pump and the auxiliary units
(agitator, water pump, etc.).
The NA power take--off is downstream of the gearbox and is

dependent on the clutch. The NA power take--off drives the
hydraulic pump for the boom and the support.
Note
In some truck models, all hydraulic pumps are driven by
clutch--dependent NA power take--offs. In these cases, the boom
hydraulic pump is driven by NA 1, and the concrete pump
hydraulic pump by NA 2.
Caution
The following points must be complied with in order to prevent
damage when switching on the power take--off:
– The operating pressure must be available on the truck before
the power take--offs are engaged (see truck manufacturer’s
technical data). Let the engine warm up to reach operating
pressure. Follow the Operating Instructions for the engine.
– The concrete pump must be switched off and the output
turned down to “0”.
– Only engage the NMV power take--off which is independent of
the clutch with the engine running and at the engine speed
specified by the truck manufacturer.
– Only engage the clutch--dependent NA power take--off with
the engine running and the clutch depressed.
5–8 A820196_05_0704
Operation
Operating and control This illustration shows examples of operating and control
elements for power elements for power take--offs. Number, appearance and location
take- offs can differ in truck models by different truck manufacturers.
Note
Be guided by the symbol on the power take--off selector and
observe the truck manufacturer’s Operating Instructions.
1 2 3 4
2 3 4
A820196_05_0704 6
No. 0 Designation
1 Indicator lamp in dashboard: Power take--off is engaged
2 Power take--off selector “1” NA
3 Power take--off selector “2” NA
4 Power take--off selector “3” NMV
Note
You must apply the parking brake before you engage one of the
power take--offs if your truck engine is equipped with electronic
diesel control (EDC). Otherwise you will not be able to increase
the engine speed during pumping operations. This is also the
case if you release the parking brake and apply it again while the
power take--off is engaged.
A820196_05_0704 5–9
Operation
Engaging the NMV Engage the NMV power take--off, which is independent of the
power take- off clutch, as follows:
(concrete pump)
" Apply the parking brake.
" Increase the engine speed as specified by the truck

manufacturer for switching the power take--offs.
" Switch on power take--off selector 3.

⇒ The indicator lamp in the dashboard lights up.
Engaging the NA Engage the NA power take--off, which is dependent on the

power take- off clutch, as follows:
(boom)
" Apply the parking brake.
" Depress the clutch pedal.
" Shift the gear lever to neutral.
" Wait a few seconds.
" Switch on power take--off selector 1 or 2.

⇒ The indicator lamp in the dashboard lights up.
" Release the clutch pedal again slowly.
Note
The procedure for disengaging the power take--offs is analogous
but in the reverse sequence.
5–10 A820196_05_0704
Operation
5.3 Setup
5.3.1 Pre-Operation Prior to operating the truck-mounted concrete pump, perform a

Inspection pre-operation inspection by checking the following items:
Note
Performing a pre-operation inspection prevents downtime and
helps maintain the truck-mounted concrete pump in proper
working condition between scheduled maintenance checks.
Warning
Defective components, structural damage, missing parts or
equipment malfunctions, jeopardize the safety of the operator
and other personnel and can cause extensive damage to the
machine. A poorly maintained machine could become the
greatest operational hazard you may encounter. It should be a
common practice that the operator perform a thorough
walk-around inspection before each day’s operation of the
concrete pump.
Note
All water, oil, and fuel levels should be checked and topped off
as necessary. The machine must be level when you check the
functional fluids. The boom and the supports must be retracted.
The water box on concrete pumps must be full during operation,
even if there is a risk of freezing.
Caution
Oils, fuel and other functional fluids may be injurious to health on
contact with the skin, etc. Always wear personal protective
clothing and equipment when you are handling toxic, caustic or
other functional fluids that are injurious to health and always take
note of the manufacturer’s information.
Warning
If any discrepancy is noted during the pre-inspection, attach a
sign at the control panel stating “DO NOT OPERATE” and repair
the discrepancy before operating the truck-mounted concrete
pump.
A820196_05_0704 5–11
Operation
• Overall machine condition:

− External structural damage
− Wheel lug nuts (missing or loose)
− Wiring and brake lines
− Condition of tires (tears, cracks or cuts, inflation)
− Missing decals, placards, warning signs
− Missing, broken or damaged parts, bolts and nuts
− Control panel, switches, gauges, volume control
− Electrical system for frayed or broken wires or loose
connections
• Engine
− Fuel level
− Oil level
− Mounting (bolts, wiring, hoses)
− Fuel or oil leaks
− Belts (fan, alternator)
• Battery
− Battery condition
− Cables and connections (ground connection)
− Battery hold down security
• Hydraulic System
− Hydraulic leaks
− Loose or damaged hoses, tubing
− Fluid level, hydraulic tank breather cap. Refill only with an
appropriate hydraulic fluid listed in the Recommended
Lubricants" section.
− Hydraulic valves and control levers
− Cleanliness of hydraulic fluid. Non−milky, bright in color
− Hydraulic cylinders, S−tube shift and delivery cylinders
• Hopper
− Grate in place, not damaged
− S−tube
− Remixer agitator, drive motors (if equipped)
− Outlet cleanliness
− Lubrication
• Boom
− Lubrication
− Missing, broken or damaged parts, bolts and nuts
− Hydraulic leaks
− Loose or damaged hoses, tubing
5–12 A820196_05_0704
Operation
5.3.2 Space Requirement
A820196_05_0704 7
The support legs must always be fully swung out and extended
Normally supported
1 2
3
A820196_05_0704 8
1 Extent of forward supports = approx. 26 ft. (8.0 m)

2 Extent of rear supports = approx. 29.6 ft. (9.0 m)
3 Support--to--support distance = approx. 28.6 ft. (8.7 m)
A820196_05_0704 5–13
Operation
One- Side- Support
1
2
A820196_05_0704 9
1 Extent of forward supports = 18.4 ft. (5.6 m)]

2 Extent of rear supports = 21.82 ft. (6.65 m)
3 Support--to--support distance = [Passenger side: 24.11 ft. (7.75 m)] [Driver side: 29.33 ft. (8.94 m)]
5.3.3 Preliminary Setup Prior to setting up the truck-mounted concrete pump, perform
the following steps:
Note
As a rule, the site management determines the setup site for the
machine and prepares the site accordingly. However, the
machine operator is responsible for setting up the machine
safely. The machine should only be set up on level ground.
Inspect the proposed site carefully and reject the setup site if
you have any doubts about the safety of the site.
1. Walk the approach route before you drive it. Ask for
someone to give you directions if you have to drive the truck
in reverse.
2. Maintain a safe distance from pits, slopes, trenches, etc.,
when approaching the setup site and when setting up. Check
the condition of the soil or flooring where the machine will be
positioned. As shown in the diagram below, the force
transferred into the ground by each outrigger is distributed
through the ground in a conical pattern at a 45˚ angle. This
imaginary cone must not exit through the wall of the pit.
Ensure that you maintain a safe distance from any pits (i.e.,
at least “a”), as mentioned below:
5–14 A820196_05_0704
Operation
A. If the ground has a good loadbearing capacity, maintain a

minimum clearance of “a” from a pit even if the pit is
shallow. The minimum clearance “a” from a pit for
machines
• up to 26,000 lbs (11,791 Kg) permissible gross
weight, is 3.3 ft. (1 m);
• over 26,000 lbs (11,791 Kg) permissible gross weight,
is 6.6 ft. (2 m)
45°
A820196_05_0704 10
Minimum Clearance “a” From a Pit
B. If the ground does not have a good loadbearing capacity,

maintain an additional safety clearance “A” from a pit. As
shown in the diagram below, the additional safety
clearance “A” from a pit:
• for loose, backfilled ground is equal to twice the pit
depth
(i.e., A y 2 pit depth T),
• for compact, solid ground is equal to the pit depth
(i.e., A y 1 pit depth T).
A820196_05_0704 5–15
Operation
Ay2 T Ay1 T
ÇÇÇÇÇÇÇÇÇ
ÇÇÇÇÇÇÇÇÇ
ÇÇÇÇÇÇÇÇÇ T
ÇÇÇÇÇÇÇÇÇÇÇÇ
ÇÇÇÇÇÇÇÇÇÇÇÇ
Additional Safety Clearance “A” From a Pit
A820196_05_0704 11
Calculation Example 1 Permissable gross weight of machine = 45,000 lbs (20,408 Kg)
(Therefore the minimum distance from the pit “a” = 6.6 ft, 2.0 m)
Type of ground = loose, backfilled; depth of pit (T) = 3 ft (0.9m)
(Therefore the additional safety clearance from the pit “A” = 2 x 3 ft = 6 ft)
Required distance from pit (i.e., greater of “A” (6.6 ft) and “A” (6 ft) = 6.6 ft
Calculation Example 2 Permissable gross weight of machine = 23,000 lbs (20,408 Kg)
(Therefore the minimum distance from the pit “a” = 3.3 ft, 1m)
Type of ground = compact, solid; depth of pit = 2 ft (6.6m)
(Therefore the additional safety clearance from the pit “A” = 1 x 2 ft = 2 ft)
Required distance from pit (i.e., greater of “A” (3.3 ft) and “A“ (2 ft) = 3.3 ft
5–16 A820196_05_0704
Operation
3. Ensure that there is clearance to extend the outrigger legs.

The outrigger legs must be fully swung out or extended.
As shown below, the outrigger’s danger zone is the zone in
which the outriggers are swung out or extended:
A820196_05_0704 12
The Outrigger Legs Must Always Be Fully Swung Out and Extended
4. Effective selection of outrigger pads is essential for safe and

reliable support of the unit in various conditions. Prior to
setup, refer to the following chart for the proper selection of
outrigger pads based on the ambient temperature, load and
ground conditions.
A820196_05_0704 5–17
Operation
EFFECTIVE OUTRIGGER PAD USAGE

Putzmeister Outrigger Pads
4.5”
Application/Condition 2” UHMW 3” Wood 3” UHMW 2” Nylon Aluminum
> 80_F Caution Yes Caution Yes Yes

Temperature1
< 40_F Yes Caution Yes Caution Yes
<45,000 lbf Yes Yes Yes Yes Yes
45,000 to 60,000 lbf No No Yes Yes Yes

Vertical Load2
60,000 to 100,000 lbf No No Caution Yes Yes
> 100,000 lbf No No Caution Yes No
Asphalt Caution Yes Yes Yes Yes
Compacted Soil No Yes Caution Caution Yes

Ground Clay Yes Yes Yes Yes Yes
Support Type3
Compacted Rock Yes Caution Yes Yes Caution
Concrete/Bedrock Yes Caution Yes Yes No
Ground Chemistry4 Yes Caution Yes Yes Caution
Yes This style pad is well suited for this application or condition
Although this is an acceptable application or condition for this style pad, it should
Caution
be used with caution or substituted by a better - matched pad.
This style pad does not match well with this application or condition. Its use is not
No
recommended and another pad should be substituted.
1 Temperatures given are a guidance only, not an absolute cut - off level.
2Each pad is rated for an induced pressure (in psi) that should not be exceeded for safe operations.
The maximum loads on every Putzmeister machine are shown on a decal attached to the leg.
3 When pads are used directly on the supporting ground: hard surfaces are best matched with UHMW
or Nylon pads, soft surfaces are best matched with wood or aluminum pads.
4 Long term performance of wood and aluminum pads could be adversely affected by high levels of
water and/or alkalis (high pH levels).
5–18 A820196_05_0704
Operation
Note
Please refer to the ACPA (American Concrete Pumping Associa-
tion) Safety Bulletin entitled ‘Setting Outriggers to Prevent Acci-
dents’ found in Appendix A at the end of the operating instruc-
tions.
5. As shown in the diagram below, ensure that there are no

voids or other ground irregularities under the outrigger feet:
A820196_05_0704 13
No Voids or Other Ground Irregularities Under The Outrigger Feet
Caution
Do not bridge voids or other ground irregularities with support
blocks or timber blocks, since these blocks may break if a point
load is applied to them. If these blocks break, the machine will
not have the necessary stability and may tip over.
A820196_05_0704 5–19
Operation
6. As shown in the diagram below, ensure that the outrigger feet

are set up on level supporting ground:
A820196_05_0704 14
Outrigger Feet Should Only Be Set Up on On Level Supporting Ground
7. Verify that the machine is supported in accordance with the

corner bearing loads and the loadbearing capacity of the
supporting ground (permissible ground pressure), by
performing the following steps:
A. Ask site management for the maximum permissible

ground pressure (i.e., loadbearing capacity of the
supporting ground).
B. Determine whether the outrigger support area is

adequate by calculating the maximum possible ground
pressure that each outrigger leg can exert using the
following equation:
Machine corner bearing load

Max possible ground pressure =
Max.
Support area
5–20 A820196_05_0704
Operation
Corner Bearing Load

The Corner Bearing Load is Stated on Each Outrigger Leg Safety Decal (as shown
below):
DANGER
6” 47,210 lbs
6”
210 kN
Permissible Ground Lb/in? L= Timber Block Length with

Pressure kN/m? Cross section of 6” x 6”
(15cm x 15cm)
Undisturbed Soil 14.5 Supporting Ground is Not
(100) Suitable for Outriggers
Asphalt 29 Supporting Ground is Not

(min. 8” thick) (200) Suitable for Outriggers
Hardcore 36.3 60”
(compacted)
(250) (150cm)
Clay, Course 43.5 50”
Clay (Firm) (300) (125cm)
Mixed Stone (Firm) 50.8 43”
(350) (109cm)
Layered Gravel (Firm) 58 37”
(400) (94cm)
72.5 30”
(500) (75cm)
100 Use PM 24” x 24” Support Pads
(750) w/o Additional Timber Blocks
Rock (fractured, 145 Use PM 24” x 24” Support Pads
weathered) (1000) w/o Additional Timber Blocks
Min. 6.6 ft A ² 2T
(2m)
T
TO BE USED WITH PAD

P/N 453593
MINIMUM LOAD RATING=520 PSI
A800866
A820196_05_0704 15
Outrigger Leg Load Limit Decal
A820196_05_0704 5–21
Operation
Support Pad
A820196_05_0704 16
Example of Support Pad (P/N A126133)
Putzmeister support pads are made of molded Ultra High

Molecular Weight (UHMW) plastic. The support pads are 24 in x
24 in (600 mm x 600 mm) in size with a minimum load rating of
350 psi (24 bar).
Warning
Always use 4 timber blocks with a cross - section of 6 in x 6 in.
(15 cm x 15 cm) each and of the length shown in the table on
the next page.. Place the 4 timber blocks together beneath the
support block as shown. The support block and the timber
blocks must always be free from grease, oil, ice, etc., as
otherwise the support leg could slip off.
5–22 A820196_05_0704
Operation
A820196_05_0704 17
Length of the Timber All types of ground support have a maximum pressure (in psi.) that
Blocks Required is allowed before unacceptable consequences will occur (i.e.
sinking or road damage). The following chart provides guidance in
this area. Notice that very few cases allow the supplied O/R pads
to be used without an additional device (i.e. railroad timbers or
specially - designed metal plates).
A820196_05_0704 5–23
Operation
Corner Bearing Load (see support leg labeling) - pounds
ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ
Permissible Max. leg load
Ground
Ground w/only PMA 20,000 30,000 40,000 50,000 60,000 70,000 80,000 90,000 100,000
Type
Pressure O/R pad
Application not recommended without special povisions for
Undisturbed
14 psi 7,800 lbs spreading loads out to not exceed ground’s support
soil
capability
ÉÉÉ
ÉÉÉ
ÉÉÉ
Asphalt (min. PMA O/R pad plus (4) 8ft long
29 psi 16,200 lbs
ÇÇÇÇ ÉÉÉ
8” thick) railroad ties (7” x 8” cross
section)
Hardcore
36 psi 20,000 lbs ÇÇÇÇ
ÇÇÇÇ
PMA O/R pad plus
EITHER (4) 6ft long
ÇÇÇÇ
(compact)
railroad ties OR
ÇÇÇÇ
double layer of 4ft
ÇÇÇÇ
long railroad tiies:
PMA O/R pad plus (4) 4ft (3) on top and (6)
ÇÇÇÇ
Clay (firm) 43 psi 24,000 lbs
long railroad ties on bottom (48” x
ÇÇÇÇ
(standard 7” x *” cross 48” surface to
ÇÇÇÇ
section) ground)
Mixed Stone
ÇÇÇÇ
ÇÇÇÇ
ÇÇÇÇ
51 psi 28,500 lbs
(firm)
ÇÇÇÇÇÇÇ
Layered Gravel
58 psi 32,400 lbs
ÇÇÇÇÇÇÇ
ÇÇÇÇÇÇÇ
ÇÇÇÇÇÇÇ
(firm)
ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ
Rock
PMA O/R pad only (600mm x 600mm)
(fractured, 145 psi 81,000
weathered)
ÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇÇ
Standard
Concrete 4000 psi ——
(cured)
Note: When using this chart, round UP the leg load value given on the machine. For example, a 58,000
lb value would use the 60,000 lb chart column.
Note: Railroad ties are shown here as they are commonly used. Other support methods are available
that can do the same job (metal plates, one end from a wood telephone cable spool reel, etc.) as long
as the load per square inch is calculated and applied as shown AND the yield strength is not exceeded.
5–24 A820196_05_0704
Operation
8. Check the clearance for extending the placing boom.
9. Ensure that the setup site is adequately ventilated. Exhaust

gases can be fatal.
Danger of poisoning
Vehicle exhaust gases contain constituents which can be lethal
or carcinogenic. Set the machine up at an adequately ventilated
site or vent the exhaust gases away from where you are work-
ing.
10. With truck engine running, transmission in neutral, and

parking brake on, engage concrete pump power take-off
(PTO), by performing the following steps:
Note
If your truck engine is equipped with electronic diesel control
(EDC) you must apply the parking brake before you switch on
the power take--off. Otherwise you will not be able to increase
engine speed during pumping operations. This is also the case if
you release the parking brake and apply it again while the power
take--off is switched on.
Caution
The following points must be complied with to prevent damage
when using power take-off gearboxes:
– The transmission must be in neutral when the power take-off
gearbox is switched on or off.
– If the engine was shut down during pumping operations and
your truck has a manual transmission, you must depress the
clutch before starting it up again.
A. Position concrete pump PTO switch (located on right side

of driver’s seat) to “PUMP” position (PTO engaged).
B. Verify that green “PUMP” light illuminates.
C. If your vehicle has a manual transmission, perform these

steps:
• Push in clutch pedal (clutch disengaged).
• Place truck transmission in proper pumping gear.
A820196_05_0704 5–25
Operation
• Let clutch pedal out (clutch engaged).

D. If your vehicle has an automatic transmission, shift
selector from “N” (Neutral) to “D” (Drive). The display
indicates “4” signifying that truck transmission is in 4th
gear lock-up (i.e., the truck transmission will remain in 4th
gear). If engine is switched off or transmission shifted to
Neutral, repeat Step 10 to reset interlocks for 4th gear
lock-up PTO operation.
Note
The truck engine will automatically throttle up approximately 200
RPM when the PTO’s are engaged and the E - stops are cleared.
5.3.4 Remote Control Setup Depending on your machine’s equipment, you are able to oper-
ate it
- using radio remote control,
- using cable remote control, or
- directly from the machine in emergency operation.
Caution
Before starting to use the remote control, press the
EMERGENCY SHUT - DOWN button on the remote control and
shift all control and monitoring devices on the remote control to
the “0” position. The boom or the pump can otherwise execute
unintended movements as soon as the remote control is
switched on.
Before switching to use the remote control, turn the “Boom

speed toggle switch” to the snail symbol and, if fitted, turn the
rotary controller to “0”. This ensures that the first boom
movements after the remote control is switched on will be
executed slowly and you will be able to get used to them.
5–26 A820196_05_0704
Operation
Caution
Carry the remote control in such a way that no control elements
can be actuated unintentionally. Do not damage the remote con-
trol cable. Incorrect functions may otherwise occur.
Never put the remote control down when the machine is in ready
mode. If this cannot be avoided in exceptional circumstances,
press the EMERGENCY SHUT - DOWN button in, disconnect the
remote control and lock the remote control unit away in the driv-
er’s cab.
Cable remote control If using a cable remote control system, perform the following
steps:
A820196_05_0704 18
Emergency Stop button and toggle switch for powering on remote control
Note
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).
A820196_05_0704 5–27
Operation
Warning
Black/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. Flip the toggle switch boom
speed to the snail symbol and the rotary controller to “0” before
beginning to use the cable remote control. This ensures that the
first boom movements after the remote control is switched on will
be executed slowly and you will be able to get used to them.
1. Verify that remote cable is connected between the electric

control box and cable remote control box.
Note
On some control cabinets, the socket into which the cable
remote control is plugged is located on the control cabinet
casing. On some control cabinets the socket is fixed to the truck
superstructure and connected to the control cabinet by a cable.
A820196_05_0704 19
Connecting the Cable Remote Control
5–28 A820196_05_0704
Operation
A. Plug the cable remote control plug into the control cabinet
and secure it.
B. Plug the connector into the cable remote control unit and
secure it.
C. Switch the Local - Remote switch on the control cabinet to

Remote.
D. Unlock the EMERGENCY SHUT - DOWN button by

turning it.
E. Sound the horn.
Note
The horn/outrigger/reset switch is used to clear the E-stop mode.
Clear the E-stop mode by pushing the horn switch up once. The
first press clears the E-stop. The second and subsequent
presses blow the horn. If the horn will not blow, recheck cable
connections, E-stop buttons, and power supplied to the electric
control box.
Radio remote control If using a proportional radio remote control system, perform the
following steps:
ÁÁÁ
ÁÁÁ
ÁÁÁ
ÁÁÁ
ÁÁÁ
ÁÁÁ
ÁÁÁ
A820196_05_0704 20
Emergency Stop button and toggle switch for powering on remote control
A820196_05_0704 5–29
Operation
Note
Proportional control means:
– The boom moves slowly on a small movement of the boom
control lever.
– The boom moves at its maximum speed on a large movement
of the boom control lever.
A. Verify that radio receiver is connected to electric control

box.
B. Verify that Local-Remote switch on electric control box is

in “Remote” position.
C. Ensure transmitter has charged battery inserted.
D. Release E-stop button, by twisting button to allow it to

pop out.
E. Verify that all functions switches are off.
F. Turn transmitter power switch on.
G. Ensure electric control box and other E-stops are

released.
5–30 A820196_05_0704
Operation
Boom speed You can adjust the boom speed to any speed by means of the
boom speed rotary controller.
The procedure for adjusting the speed of boom movement is as

follows:
ÁÁÁ
ÁÁÁ
ÁÁÁ
A ÁÁÁ
ÁÁÁ
ÁÁÁ
ÁÁÁ
A820196_05_0704 21
Cable Remote Control Radio Remote Control

Toggle switch for adjusting boom speed.
1. Press the EMERGENCY SHUT - DOWN button on the remote

control.
2. Set the toggle switch to the “Snail” symbol.
3. Switch on the cable remote control system.
4. Set the boom speed required by trial and error using the
boom speed toggle switch on cable remote control and/or
boom speed toggle switch and store and delete toggle switch
(A).
A820196_05_0704 5–31
Operation
Restarting the pump If you have stopped the machine while pumping by pressing the
EMERGENCY SHUT - DOWN button on the remote control, you
must proceed as follows for restarting:
ÁÁÁÁ
ÁÁÁÁ
ÁÁÁÁ
ÁÁÁ
ÁÁÁ
ÁÁÁ
A820196_05_0704 22
Cable Remote Control Radio Remote Control

Press - Lock EMERGENCY SHUT - DOWN
Turn - Unlock EMERGENCY SHUT - DOWN
1. Unlock the EMERGENCY SHUT - DOWN button by turning it.
2. Sound the horn.
3. Switch the pump off first, and then back on again.

• Twist emergency stop (E-stop) button to allow it to pop out.
4. Ensure electric control box and other E-stops are released.
5–32 A820196_05_0704
Operation
5.3.5 Outriggers Setup
1. On cable or radio remote control, place horn/outrigger/reset

switch in outrigger position.
Warning
You must have read the safety regulations and have completed
the operations for setting up the machine before you begin
setting out the machine outriggers. The machine outriggers may
only be used under the following conditions:
– the pump drive engine is running;
– the power take--off is engaged (i.e., the machine is set to
pumping operations);
– the “Outrigger” function has been selected at the remote con-
trol or on the control block.
It is absolutely forbidden to move the outriggers manually
(mechanically).
A820196_05_0704 23
Do not move the hydraulic support legs manually
A820196_05_0704 5–33
Operation
2. As shown in the diagram below, unlock the outrigger legs by

performing the following steps:
A. Pull out pin (1).
B. Pull the lever on the snaplock upwards (2).
2.
1.
A820196_05_0704 24
Outrigger snaplock - You must unlock the outrigger legs before you are able to
extend them or swing them out.
Note
Extendable support legs are automatically locked by the sna-
plock once the support leg is fully extended.
Once the legs are locked, replace the spring pin. The snaplock
cannot now be opened unintentionally and the support leg re-
mains locked in the end position.
The snaplock has no function once swing - out support legs have
been swung out. Do not replace the spring pin; in this way the
supports will be locked automatically when they are swung back.
Before driving off, make sure that all the snaplocks are secured
by a spring pin.
Caution
Do not attempt to reposition any outrigger unless placing boom
is in stowed position. The placing boom will not operate when
the outriggers are activated.
5–34 A820196_05_0704
Operation
5.3.6 Danger Zone
A800005
A820196_05_0704 25
The danger zone when setting out the machine supports

is the zone in which the supports are swung out or
extended.
Danger of crushing
There is a danger of crushing in the area through which the sup-
ports may be swung out or extended.
You should therefore secure the danger zone. Keep the danger
zone under constant observation.
You must halt work immediately and press the EMERGENCY
SHUT--DOWN button if anyone enters the danger zone.
Uncontrolled movements of the support legs increase the risk of
accident. They are possible if:
– the hydraulic system has not been carefully bled;
– lines or threaded unions are leaking;
– there is too little hydraulic fluid in the reservoir;
– the switch is defective or dirty.
In this case, the support legs may move as soon as the prese-
lect switch is actuated.
Halt work immediately. You can continue working only after the
causes have been remedied and perfect functioning of the ma-
chine is ensured.
Caution
The support legs must always be swung out or extended to their
maximum extent. Only in this way will the machine achieve the
necessary stability.
A820196_05_0704 5–35
Operation
5.3.7 Extending Front The forward support legs can be extended and retracted using
Support Legs the left (driver’s side) and right (passenger’s side) support
control block. Both the left side (driver’s side) and right side
(passenger’s side) control blocks are illustrated below.
Warning
The forward support legs are doubly telescopable. You must
always extend the support leg and the support leg box fully. In
intermediate positions, there is a danger that the support leg
could buckle and the machine fall over.
Extending left front

support leg
A800031
2 3 4 5
A820196_05_0704 26
Extending left front support leg with left side support control block
1 Preselect lever
2 Raise/lower left front (LF) support pad
3 Raise/lower left rear (LR) support pad
4 Extend/retract left front (LF) support leg
5 Extend/retract left rear (LR) support leg
Proceed as follows to extend the left front support leg:
" Press the preselect lever (1) downwards to activate the

function.
" Pull lever (4) upwards to extend the LF support leg.
5–36 A820196_05_0704
Operation
" Release the preselect lever (1). It returns automatically to

the 0 position.
" Do the same on the other side of the truck.
Extending right front

support leg
A800029
5 4 3 2 A820196_05_0704 27
Extending right front support leg with right side support control block
1 Preselect lever
2 Raise/lower right front (RF) support pad
3 Raise/lower right rear (RR) support pad
4 Extend/retract right front (RF) support leg
5 Extend/retract right rear (RR) support leg
Proceed as follows to extend the right front support leg:

function.
" Pull lever (4) upwards to extend the RF support leg.

the 0 position.
A820196_05_0704 5–37
Operation
5.3.8 Swing Out (extend) The rear support legs can be swung in (retracted) or out
Rear Support Legs (extended) using the left and right support control block as
shown below.
Swinging out
(extending) left rear
support leg
A800031
A820196_05_0704 28 2 3 4 5
Swing out (extending) left rear support leg with the left side support control block
1 Preselect lever
5 Swing out (extend)/swing in (retract) left rear (LR) support leg
Proceed as follows to swing out the left rear support leg:

function.
" Pull lever (5) upwards to swing out the LR support leg.

the 0 position.
5–38 A820196_05_0704
Operation
Swinging out
(extending) right rear
support leg
A800029
5 4 3 2 A820196_05_0704 29
Swing out (extending) right rear support leg with the right side support control block
1 Preselect lever
5 Swing out (extend)/swing in (retract) right rear (RR) support leg
Proceed as follows to swing out the right rear support leg:

function.
" Pull lever (5) upwards to swing out the RR support leg.

the 0 position.
A820196_05_0704 5–39
Operation
5.3.9 Lower Front Support The forward support pads can be raised or lowered using the left
Pads and right outrigger control block as shown below.
Lowering left front

support pad
A800031
A820196_05_0704 30 2 3 4 5
Lower left front support pad with the left side support control block
1 Preselect lever
Proceed as follows to lower the left front support pad:

function.
" Pull lever (2) upwards to lower the LF support pad.

the 0 position.
5–40 A820196_05_0704
Operation
Lowering right front

support pad
A800029
5 4 3 2 A820196_05_0704 31
Lowering right front support pad with the right side support control block
1 Preselect lever
Proceed as follows to lower the right front support pad:

function.
" Pull lever (2) upwards to lower the RF support pad.

the 0 position.
A820196_05_0704 5–41
Operation
5.3.10 Lower Rear Support

Pads
Lowering left rear
support pad
A800031
A820196_05_0704 32
2 3 4 5
Lower left rear support pad with the left side support control block
1 Preselect lever
Proceed as follows to lower the left rear support pad:

function.
" Pull lever (3) upwards to lower the LR support pad.

the 0 position.
5–42 A820196_05_0704
Operation
Lowering right rear

support pad
A800029
5 4 3 2 A820196_05_0704 33
Lowering right rear support pad with the right side support control block
1 Preselect lever
Proceed as follows to lower the right rear support pad:

function.
" Pull lever (3) upwards to lower the RR support pad.

the 0 position.
Caution
Only execute one outrigger at a time. Observe leveling bubble
and ensure that truck remains level as each outrigger is
positioned. Stability is jeopardized at a deviation from horizontal
of 3_ or more.
A820196_05_0704 5–43
Operation
5d
3d
1
A820196_05_0704 34
Leveling bubble
1 Permissible range of tilt
Note
Extend the outriggers one after the other until the truck lifts
about 5 cm (2 inches) from the ground. The rear wheels may be
in light contact with the ground in order to achieve “steady pump-
ing”.
Warning
All four outriggers must be completely swung out and extended
to stabilize the truck-mounted concrete pump placing boom
through swing, unfolding, extending, and elevate functions.
Wrong positioning or partial opening of outriggers can cause
machine instability and risk of overturning.
Warning
Uncontrolled movements of the outrigger legs increase the risk
of an accident. They are possible if:
– the hydraulic system has not been carefully bled;
– pipes or threaded unions are leaking;
– there is too little hydraulic fluid in the reservoir;
– the switch is defective or dirty.
In this case, the support legs may move as soon as the
preselect switch is actuated. Halt work immediately. You can
continue working only after the causes have been remedied and
perfect functioning of the machine is ensured.
5–44 A820196_05_0704
Operation
3. After outriggers are positioned, on the radio or cable remote

control, return the horn/outrigger/reset switch to its center
(off) position to activate the boom controls.
5.4 Special Case of Busy traffic conditions and space problems on construction sites
“One--Side--Support” sometimes do not allow the support legs to be swung out or
extended fully. In special circumstances of this nature, you may
set up the machine with “One--Side--Support” as described
below.
Warning
This arrangement of supports should be the exception.
Wherever possible, you must set out the machine’s supports
such that all support legs are swung out and extended to their
normal end position.
Follow the instructions precisely when using “One--Side Support”

and work with great care. As a precaution, use timber blocks that
are greater than necessary beneath the support plates. This will
prevent the stability being additionally endangered by a support
foot sinking.
Maintain the necessary distance from pits, slopes and similar

when using One--Side--Support.
The forward support leg on the restricted side should be lowered

in the fully retracted position (since intermediate positions are
not permitted).
A820196_05_0704 5–45
Operation
5.4.1 Supporting the

machine
A820196_05_0704 35
1 Construction site
" Drive the machine up to the proposed site of operations so

that it is parked approximately at right--angles to the
construction site.
Caution
Limit switches are mounted on the boom, these permit a
restricted, secure working range for the machine when using
One--Side--Support. So that the machine is safely set up within
the restricted working range, you must swing out and extend the
swinging support legs on the working side right out to the normal
end position.
5–46 A820196_05_0704
Operation
A820196_05_0704 36
Supports on the working side

1 Construction site
" First support the machine on the working side.
>1m
A820196_05_0704 37
Swing out the rear support leg on the restricted side

1 Construction site
A820196_05_0704 5–47
Operation
" Swing the rear support leg on the restricted side out at
least one metre.
Caution
The forward support leg must be either fully extended or fully
retracted. Intermediate positions are not permitted, as they can
lead to significant damage to the machine and can impair
stability.
You should therefore leave the forward support leg on the

restricted side retracted when you are using One--Side--Support
to set the machine up.
A820196_05_0704 38
Lowering the forward support foot

1 Construction site
" Place support plates and timber blocks beneath the sup-
port feet on the restricted side.
" Support the machine by lowering the support feet.
5–48 A820196_05_0704
Operation
5.4.2 Restricted working

range
A820196_05_0704 39
1 Working range when using One--Side--Support
Note
The working range when using One--Side--Support is around
120_, calculated from the transport position of the boom.
A820196_05_0704 5–49
Operation
5.5 Boom Movements Before you extend the placing boom you must read the safety
regulations and complete the operations to set up the machine.
You may only extend the placing boom once you have set the
machine up properly. Comply with the safety regulations of the
country in which you are using the machine in every case.
Prohibited Activities
A820196_05_0704 40
Prohibited Activities
Caution
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.
Overlapping Working
Ranges
Caution
Take note of the working ranges of other machinery that is
working near you (e.g., cranes, other concrete placing booms,
etc.)
5–50 A820196_05_0704
Operation
5.5.1 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 and Shift the placing boom to the transport position in the event of
Storms storms or bad weather.
-- Placing booms with a vertical reach of 42 m or more (M 42
and larger) may only be operated in wind speeds up to 38
mph (61 km/hr wind force of 7).
-- Placing booms with a vertical reach less than 42 m may only
be operated in wind speeds up to 46 mph (74 km/hr wind
force of 8).
Higher wind speeds jeopardize stability and the safety of
structural elements. 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 there is a perceptible hindrance to walking in the open.
• In winds of force 8 and greater, small branches break from
trees and walking outside is made significantly more difficult.
Cold Weather The boom may not be used in temperatures below +5 F_

(--15 _C.) There is a danger of damage to the steel (brittle
fracture) and the seals throughout the system at these
temperatures. In addition, these 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. During
cold weather, if hydraulic fluid is not at normal operating
temperature, then boom operation may be sluggish.
A820196_05_0704 5–51
Operation
5.5.2 Signal of Boom

Movements
A820196_05_0704 41
Sound the Horn First, Then Move
To sound the horn, press the yellow signal horn button located
on right hand side of hopper or press the horn + deactivate
Emergency Shutdown toggle switch twice (first press clears
E--stop) on cable or remote control.
Note
Move the placing boom with cautious operation of the controls.
Maintain visual contact with the site of concrete placement.
Warn by sounding the horn before you move the boom.
5.5.3 Temperature-Related The hydraulic fluid heats up to an average temperature of 140˚--

Cylinder Movements 158˚F (60˚-- 70˚ C) during operation because of the friction in
the lines. When the hydraulic fluid cools, its volume reduces as
cold hydraulic fluid has a smaller volume than does hot hydraulic
fluid. This causes the cylinders on the boom, swing--out legs and
outriggers to retract a little, which causes the boom to move and
the outrigger feet to sink.
Caution
The boom can move during lengthy pauses in work due to cool-
ing of the hydraulic fluid. For this reason you should never leave
the boom in the extended position during breaks in working.
In addition, you must keep the outriggers under constant ob-
servation while the machine is in operation. You may have to re-
adjust the swing--out cylinders and outrigger cylinders.
5–52 A820196_05_0704
Operation
The extent to which the boom and the truck move depends on
the extent to which the various boom and outrigger cylinders
have been extended and the magnitude of the temperature
difference in the hydraulic fluid.
5.5.4 Uncontrolled Boom The following defects may be the cause of uncontrolled boom
Movements movements:
-- Malfunctions 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.
Caution
In no event should you first press the EMERGENCY
SHUT--DOWN 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:
1. Counter the uncontrolled movement immediately and attempt

to steer the boom out of the danger zone and bring it to rest
under control.
A820196_05_0704 5–53
Operation
2. If the uncontrolled boom movement continues, despite

countermeasures, press the EMERGENCY SHUT--DOWN
button.
Note
Repeated practice is required to ensure that it will be possible to
implement the measures described above in an emergency.
5.6 Hand Signals for Pump operators and persons guiding them must agree on
Boom and Pumping unambiguous hand signals before commencing work.
Operations Suggestions for the most important hand signals are made in
this section. They are based on ACPA Safety Manual Hand
Signals. The direction of movement is specified from the
machine operator’s direction of view.
A820196_05_0704 42
ACPA Hand Signals
5–54 A820196_05_0704
Operation
5.7 Unfolding the Follow the sequence specified for unfolding the 5 RZ boom. The
5 RZ Boom boom must be folded in the reverse sequence.
Note
You must unfold the arm assembly to the side of the truck to
maintain the lowest possible unfolding height.
Caution
Always observe the specified sequence for folding and unfolding
the boom. Failure to comply with the sequence may allow the
crank lever in the D hinge to compress the delivery line, adjacent
hydraulic cylinders or other components.
Take extreme care when unfolding the boom. Look out for any
obstacles which may obstruct the boom as it is being unfolded.
You should further note that the end hose (depending on the
machine’s equipment) is positioned loosely in the end hose
brackets and hangs down freely when the boom is being folded
in and out.
A820196_05_0704 5–55
Operation
5.7.1 Unfolding sequence
60˚
A820196_05_0704 43
Raising arm 1
" Raise arm 1 through approximately 60˚.
A820196_05_0704 44
Slewing the placing boom
5–56 A820196_05_0704
Operation
" Slew the placing boom in the required direction.
Caution
If the machine is equipped with end hose brackets without
locking mechanisms, you will require more clearance beneath
the arm assembly when this is being unfolded to ensure that the
end hose does not scrape along the ground.
A820196_05_0704 45
Unfolding arm 2
" Unfold arm 2 in such a way that you can then unfold the
remaining arms without any problems.
A820196_05_0704 5–57
Operation
A820196_05_0704 46
Unfolding arm 3
" Unfold arm 3.
Caution
Before you unfold arm 4, you must unfold arm 5 through
approximately 15_, so that the boom tip is approximately 1 m
away from the D hinge (hinge between arm 3 and arm 4). The
crank lever on the D hinge will press against the pipe bend at the
boom tip if you do not follow this instruction.
15˚
A820196_05_0704 47
Unfolding arm 5
5–58 A820196_05_0704
Operation
" Unfold arm 5 approximately 15_.
End hose brackets

without locking
mechanisms
A820196_05_0704 48
Unfolding arm 4
" Unfold arm 4.
A820196_05_0704 49
Unfolding arm 5
" Unfold arm 5.
A820196_05_0704 5–59
Operation
End hose brackets

with locking
mechanisms
A820196_05_0704 50
Unfolding arm 4
" Unfold arm 4.
Note
If the machine is equipped with end hose brackets with locking
mechanisms, you must unfold arm 4 further to enable you to
release the end hose after arm 5 is unfolded.
A820196_05_0704 51
Unfolding arm 5
" Unfold arm 5 enough to allow you to unlock the end hose.
5–60 A820196_05_0704
Operation
End hose
A820196_05_0704 52
Unlocking the end hose
" Unlock the end hose by pulling the two locking levers
downwards.
A820196_05_0704 53
Unlocking the end hose
A820196_05_0704 5–61
Operation
5.7.2 Impermissible
working range
A820196_05_0704 54
1 Area in which work with the end hose is not permitted
Caution
The end hose must not be shifted behind the vertical of the
boom.
Raising arm 1
" Raise arm 1 through approximately 60˚.
Unfolding arm 3
" Unfold arm 3.
5–62 A820196_05_0704
Operation
5.8 Unfolding the Boom If you have set up the machine using One--Side--Support you
when using must only unfold the boom as described below.
One--Side--Support
Caution
The working range must have been preselected using the OSS
keyswitch on the control cabinet when the boom is unfolded
using One--Side--Support, as otherwise the safe working range
of 120_ is not secured. The consequence of this could be that
you would be able to slew the boom into the prohibited working
range and the machine would tip over.
Once you have preselected the working range, you must take
the key from the OSS keyswitch and keep it on your person, to
ensure that no unauthorized person can change the preselec-
tion.
Note
The working range in the example described below is on the
right--hand side of the truck (passenger side).
A820196_05_0704 5–63
Operation
A820196_05_0704 55
" Turn the OSS keyswitch on the control cabinet towards the
required working range.
⇒ The markings on the OSS keyswitch point towards the
symbol corresponding to your support.
⇒ The green indicator lamp for the selected working
range on the control cabinet lights up.
⇒ The yellow flashing beacon for the selected working
range on the boom pedestal lights up.
" Remove the key from the OSS keyswitch and put it away.
Caution
If the indicator lamp on the control cabinet and the flashing
beacon on the boom pedestal light up the wrong way may
indicate a fault in the electrical system. In this event you do not
use the OSS facility.
5–64 A820196_05_0704
Operation
Caution
crank lever in the D hinge to compress the delivery line, adjacent
hydraulic cylinders or other components.
You should further note that the end hose (depending on the ma-
chine’s equipment) is positioned loosely in the end hose brack-
ets and hangs down freely when the boom is being folded in and
out.
90˚
A820196_05_0704 56
" Raise the boom to the vertical.
A820196_05_0704 5–65
Operation
Caution
It may be necessary for you first to slew the boom through the
prohibited working range. This will depend on how the boom was
previously positioned.
Only slew the boom through the prohibited working range when
it is pointing vertically upwards.
A820196_05_0704 57
" Slew the boom to the desired working range.
5–66 A820196_05_0704
Operation
Checking the working range restriction
A820196_05_0704 58
Note
Once you have slewed the boom into the desired working range,
you will only be able to slew the boom to the boundary of the
working range. The slewing movement will be stopped by limit
switches when the boom is slewed to the boundary. You will then
only be able to slew the boom in the opposite direction.
Caution
The limit switches for the working range restriction must be
checked before each job.
You must cease OSS working and set out the machine supports
fully if you should determine in your inspection of the working
range restriction that the limit switches are not operating perfect-
ly.
" Slew the boom fully to the left and fully to the right until the
slewing movement is stopped automatically in each case.
A820196_05_0704 5–67
Operation
Switching off the

flashing beacon
A820196_05_0704 59
" You may switch off the flashing beacon on the control cabi-
net after testing the limit switches.
" Continue unfolding the arm assembly, as described in the

“Unfolding the Boom” section.
5–68 A820196_05_0704
Operation
5.9 Pumping Operations You must carry out the following operations before you start to
pump:
-- Set the machine up for work properly (see “Starting Up”
section).
-- Set the machine supports out properly (see “Supporting the
Machine” section).
-- Carry out all necessary function checks (see “Function
Checks” section).
-- Extend the boom to the desired working position (see
“Extending the Placing Boom” section).
5.9.1 Hazards Dangers to the life and limb of site personnel can arise at many
points during pumping operations. You can minimize these
dangers by observing the following notes.
End Hose Striking Out
2
A820196_05_0704 60
1 Maximum end hose length 13.1 ft. (4 m)

2 Danger zone = 2 × end hose length = 26.2 ft. (8 m)
Warning
There is a risk of injury in the area around the end hose if the
end hose swings out violently 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 nobody is standing in the danger zone. Keep the
danger zone under constant observation.
You must halt work immediately and press the EMERGENCY
SHUT--DOWN button if anyone enters the danger zone.
A820196_05_0704 5–69
Operation
Incorrect Use of
the End Hose
A820196_05_0704 61
Warning
Never bend the end hose over. Never attempt to straighten a
bent end hose by increasing the pressure. The end hose must
not be inserted 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.
Sucking in Air
A820196_05_0704 62
Agitator Hopper Escaping Compressed Air
5–70 A820196_05_0704
Operation
Warning
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 agitator hopper with concrete
up to the mixer shaft during pumping operations.
5.9.2 Notes on Correct To supplement the notes given here, you will find comprehensive
Pumping information on the following subjects in our “Concrete
technology” pamphlet (BP 2158):
-- Concrete components
-- Properties of freshly--mixed concrete
-- Properties and conditions of freshly--mixed concrete
when pumping
-- Guide to avoid faults
-- Specifications and regulations of the “Technical Regulations”
You may request this pamphlet from Putzmeister’s Customer
Support Group should you not already have a copy.
Bouncing Boom
Note
If the boom bounces very heavily in pumping operations, check
the support and correct it as required. Calm pumping is achieved
if the rear wheels are in light contact with the ground. Do this by
retracting the rear support feet until the rear wheels are in
ground contact and then retract the support feet about
another .4 inches (1 cm).
If the support is correct, reduce the pump speed or change the
boom position.
The boom can also bounce if air is taken in and compressed in
the delivery line. You should therefore always make sure that the
agitator hopper is always filled with concrete to the mixer shaft
and that no air is sucked in.
A820196_05_0704 5–71
Operation
Favorable Boom
Position
A820196_05_0704 63
Last Arm in a Horizontal Position
Note
A horizontal position of the last arm is favorable 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. If the arm position is horizontal, the boom is
moved forwards and backwards, which causes a light rocking
motion.
5–72 A820196_05_0704
Operation
Damping Valve As shown in the diagram below, the damping valve is used to
control the switching speed of the transfer tube.
A820196_05_0704 64
Hare: Damping Valve Switch Position Open

Snail: Damping Valve Switch Position Closed
Note
You must close the damping valve when you are pumping soft
consistence concrete (snail symbol) as otherwise the transfer
tube switches over too harshly.
You must open the damping valve (hare symbol) when you are
pumping stiff consistence concrete as the concrete has a
damping effect.
5.9.3 Starting Pumping The process from the start of concrete pumping to the time at
which a continuously flowing concrete stream exits from the end
hose is known as starting to pump. The entire delivery line must
be wetted at the start of pumping operations by performing the
following steps:
A820196_05_0704 65
Starting Pumping with Thin Concrete
A820196_05_0704 5–73
Operation
1. Insert two sponge balls into the delivery line through the
wash--out port.
2. Pour approximately 0.65 yd.3 (0.5 m3) thin concrete into the
hopper.
3. Switch the agitator on.
4. Slowly pump the concrete into the delivery line. The process
of starting to pump with thin concrete is completed when the
two sponge balls and a solid concrete stream exit from the
end hose.
Note
You must begin pumping with a priming agent if the delivery
lines are new, or if the delivery line has not been used for a long
time. This priming agent could be either a cement-water mixture
(grout) or a specially designed agent such as the “Putz Pack
Primer.”
5.9.4 Pumping Commence pumping concrete by performing the following steps:

1. Mix the concrete vigorously in the truck mixer at maximum
speed. Ensure that the concrete mix is uniformly prepared.
Correct mixing of the concrete influences pumping
performance.
2. Add concrete additives (deflocculants, set retarding
admixtures) and mix for at least a further four minutes.
3. Pour the concrete from the truck mixer, silo, etc. into the
agitator hopper.
4. Switch the agitator on.
5. Begin delivery.
Note
Start with a low output and increase this continuously after
several cubic yards (meters).
Breaks in Pumping You should avoid breaks in pumping as far as possible, as the
concrete in the delivery line can start to set, or can become
segregated due to the vibrations of the machine. Note the
following points if breaks are unavoidable:
-- Never leave the delivery line under pressure;
5–74 A820196_05_0704
Operation
-- Relieve the delivery line during short breaks in delivery by

reverse pumping briefly (2--3 strokes). Move the concrete at
short intervals by forward and reverse pumping;
-- You should avoid breaks when pumping concrete with a high
slump (i.e., concrete that has a tendency to separate the grout
from the aggregate) as the vibrations can segregate the
concrete; When you restart pumping, you must leave the
pump switched to reverse pumping until the transfer tube
switches across fully on both sides. Only then can you switch
over to forwards pumping again.
-- Pump the concrete back into the agitator hopper before long
breaks in pumping. You must mix the concrete again before
you recommence pumping.
Caution
Never use force to pump segregated concrete or concrete that
has become lumpy because it is beginning to set into the
delivery line. Blockages can very easily be caused in this way.
The boom can sink during lengthy breaks in pumping as a result
of the hydraulic fluid cooling. For this reason you must never
leave the boom unattended in the extended position during
breaks.
A820196_05_0704 5–75
Operation
5.9.5 Pumping in Putzmeister’s exclusive Econo--Geart feature is included on all

Econo--Geart BSF models built on a Mack Truck chassis. The Econo--Geart
feature can provide significant fuel savings in applications where
high power demands are not required.
Econo--Geart works similar to ‘overdrive’ on an automobile.

When pumping concrete in applications where engine power
demands are not high, place the transmission shift lever into the
appropriate Econo--Geart speed range on the shift plate. By
doing so the engine runs at a significantly lower engine speed and
a reduced amount of fuel is consumed. The lower engine speed
also reduces the engine torque and power output. Therefore, it
must be understood that Econo--Geart is not meant for use in
conditions where high engine power is required. If, while working
in the Econo--Geart mode, the engine becomes sluggish or loses
power, immediately shift the transmission out of Econo--Geart
and into the standard gear range for pumping.
The following chart shows the standard pumping gear, as well as,
the Econo--Geart for each of the chassis options:
Chassis Transmission Standard Gear Econo--Geart

3 & 4 axle chassis 10 speed 9th 10th
6 & 7 axle chassis 18 speed 7th High 8th High
5–76 A820196_05_0704
Operation
5.9.6 Possible Faults Faults may occur even if you have observed all the notes on
correct pumping. This section lists the faults occurring most
frequently, and indicates how to rectify them.
Blockages
2
1
3
A820196_05_0704 66
1 Wedged aggregate
2 Cement paste
3 Boundary layer
The following faults can lead to blockages:

-- delivery line insufficiently wetted;
-- transfer tube leaking;
-- lines leaking;
-- concrete leavings in the transfer tube and delivery pipes;
-- unfavorable concrete composition;
-- segregated concrete;
-- set concrete.
Caution
In the event of blockages, pump the concrete immediately back
into the agitator hopper and mix it up. You can switch over to
forwards pumping when the delivery cylinders and the transfer
tube are switching over automatically again without problem.
Begin pumping again with care.
Overheating Continuous operation under high loading can lead to overheating

of the hydraulic fluid. All pumps have a thermo--electrical
cut--out. The pump is automatically shut down if the fluid heats
up to over 194_F (90_C). Proceed as follows to prevent this:
A820196_05_0704 5–77
Operation
1. Check that the hydraulic fluid radiator is operating correctly. If

not, you can switch it on using the toggle switch on the
control cabinet.
2. Reduce the output.
3. As shown in the diagram below, fill the water box with fresh
water as soon as the fluid temperature rises above 176_F
(80_C).
A820196_05_0704 67
Cooling -- Water box is shown with grate removed for illustration purposes only.
Grate should not be removed unless a qualified mechanic is performing an
approved maintenance procedure.
4. Change the water continuously if the temperature continues
to rise.
5. Look for the cause of fluid overheating and rectify it.
6. As shown in the diagram below, if you absolutely must supply
additional cooling, direct the water jet onto the drive cylinders
and the piston rods of the drive cylinders.
A820196_05_0704 68
Additional Cooling
Caution
Never spray water on the hydraulic fluid reservoir because
damage may be caused to the hydraulic pump. Also never use
sea water or water containing salt for cooling because this will
destroy the chrome layer on the delivery piston rods and delivery
cylinders.
5–78 A820196_05_0704
Operation
Restarting After If the pump was switched off because of overheating, restart the
Overheating pump by performing the following steps:
1. Switch the pump off.
2. Never switch the engine off, as the hydraulic fluid radiator

must remain in operation.
3. Refresh the water in the water box.
4. Wait until the hydraulic fluid has cooled if you are not able to
find the fault immediately.
5. Once the red indicator lamp has extinguished, switch the

pump back on and continue pumping slowly at reduced
output.
6. Determine the cause of the fluid overheating once pumping

operations have been completed and rectify the fault.
5.9.7 Special Cases On some construction sites, it may be the case that the net
reach of the boom is not adequate. You then have the option of
connecting a continuation delivery line to the boom tip or, if your
machine is equipped with a lateral outlet, connecting a delivery
line there.
Continuation
Delivery Line
A820196_05_0704 69
Connect Continuation Delivery Line
A820196_05_0704 5–79
Operation
Caution
No forces must be transferred from the fixed delivery line to the
boom or vice versa.
The stationary delivery line may not place additional loading on
the boom. This will jeopardize the stability of the machine.
The delivery hose should not be bent or stretched. Blockages
can occur if it is bent. If it is stretched out, forces may be
transmitted which can lead to damage to the structure, delivery
hose or boom.
The boom can sink during pumping operations and place the
delivery hose under tension as a consequence of cooling of the
hydraulic fluid in the boom cylinders. This can cause forces to be
transferred or the delivery hose to tear. You should therefore
keep the delivery hose under constant observation.
1. Extend the boom to bring the last arm approximately 4.9--6.6

ft. (1.5--2 m) from the stationary delivery line.
2. Dismantle the end hose.
3. Mount a 9.8 ft. (3 m) long delivery hose in place of the end

hose.
4. Connect the delivery hose and the fixed delivery line using a
SKH attachment coupling. Use an A seal as the seal.
5. Fasten the SKH attachment coupling securely to the

structure.
5–80 A820196_05_0704
Operation
5.10 Cleaning
5.10.1 Preparations for Prior to cleaning the concrete pump, perform the following steps:
Cleaning
Note
Concrete leavings that are deposited inside the delivery line or
transfer tube can cause damage and will reduce the
cross-section as they accumulate. A clean delivery line and
transfer tube is therefore indispensable if you wish to be able to
start pumping without problems on the next job. When cleaning,
adhere to the following instructions:
– Concrete leavings deposited around the wear ring can impair
its function. For this reason, thorough flushing of the wear ring
is required at the end of a job, unless the next pumping job
follows within 30 minutes.
– Only use cold water at a maximum water pressure of 73.5 psi
(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 jet equipment or other
devices.
– Never use sea water or other water containing salt for
cleaning purposes. You must rinse off any sea water that gets
on the machine.
– Lock the remote control units away in the driver’s cab during
cleaning operations. The remote control units do not have a
watertight casing. Execute the machine functions required
during cleaning operations from the control cabinet.
Warning
Leave the hopper grate closed during all cleaning operations,
since you could be trapped by the agitator.
A820196_05_0704 5–81
Operation
A820196_05_0704 70
Do not reach into the hopper.
1. Find an appropriate use for the leavings to help in

environmental protection.
The leavings should be used on the construction site. The leav-
ings should be used as building rubble or be recycled if this is
not possible:
– We recommend that you use a suitable sized tarp (with
grommets for hoisting) to allow you to make use of the
remaining concrete. You can lay the tarp down under the
hopper before opening the hopper flap. The concrete then
flows out onto the tarp and can be transported to the site of
concrete placement using a site crane.
– If the concrete is not to be used, you should bend a length of
reinforcing steel into a hook and insert it in the concrete. Once
the concrete has cured, you can transport the lump of
concrete away using a site crane.
2. Ensure that you have a sufficient numbers of sponge balls

and other cleaning accessories to clean the machine
properly.
5–82 A820196_05_0704
Operation
2
4
A820196_05_0704 71
Sponge Balls and Other Accessories

1 Sponge pig
2 Sponge cube
3 Sponge ball
4 Wash-out pig
3. As shown in the diagram below, use the catch basket if you

wish to force the concrete out of the end of the pipe using
water pressure or compressed air. It must be designed such
that the concrete can flow out unhindered, but that the
sponge ball (cube, pig) is trapped and that this
simultaneously seals off the delivery line.
4
A820196_05_0704 72
Catch Basket
A820196_05_0704 5–83
Operation
1 Coupling
2 Catch basket (closed pipe section)
3 Spring pin (on both sides)
4 Catch bracket
Caution
Remember that:
– The use of the catch basket is recommended when water is
used to force out the concrete, to ensure that the delivery line
is sealed off, and no water can escape.
– A catch basket on the end of the delivery line is an absolute
requirement if you are forcing the concrete out using
compressed air, as otherwise there is a risk of injury from the
wash-out sponge and concrete as they are expelled.
– There is an increased risk of accident when cleaning with
compressed air. The cleaning operation must only be carried
out by a subject expert or under his supervision. Putzmeister
accepts no liability for damage caused by incorrect
implementation of compressed air cleaning. All persons
participating in the cleaning operation must be instructed in
the safety regulations.
4. As shown in the diagram below, use the wash-out adaptor

when the machine is cleaned using water under pressure or
compressed air.
3 2 1
A820196_05_0704 73
Wash-Out Adapter
5–84 A820196_05_0704
Operation
1 Connection for water or compressed air

2 Isolating valve for connection
3 Pressure dump bend
4 Pressure dump cock
5. If you wish to use cement bags for high pressure water

cleaning, perform the following steps:
A. As shown in the diagram below, roll up 1 -- 2 empty

cement bags together.
B. Immerse the rolled--up cement bags in water for about

5 minutes before starting the cleaning operation.
A820196_05_0704 74
Rolled--up Cement Bags
Note
Cement bags soaked in water and rolled up have proved useful
when cleaning the delivery line using water under pressure. The
cement bags prevent the washing water penetrating the
concrete, flushing the concrete out and causing blockages.
Note
You may also prepare a short pipe section containing the ce-
ment bags and a wash--out sponge before you start the cleaning
operation.
A820196_05_0704 75
6. Prior to cleaning the wear ring and seal ring on the transfer
tube, the water hose must be marked to ensure that the hose
does not get cut by the switching transfer tube during
cleaning. Mark the water hose by performing these steps
(refer to diagram below):
A820196_05_0704 5–85
Operation
A. Measure the hose length required on the outside of the

transfer tube. The nozzle on the hose should be located
shortly before the seal ring so that concrete leavings are
washed away from the area around the wear ring and
seal ring when the nozzle is set to spray.
B. Mark the measured length on the hose with adhesive
tape, or similar.
Note
The best way to clean the wear ring and seal ring on the transfer
tube is to rinse this area with water for some time from close up.
Warning
The machine must be switched off and the hydraulic system,
including the accumulator, fully depressurized when you are
measuring the hose length required, as otherwise there is a risk
of injury as the transfer tube switches over.
A820196_05_0704 76
Marking the Water Hose

1 Adhesive tape marking
" Measure the hose length required on the outside of the

transfer tube. The nozzle on the hose should be located
shortly before the seal ring so that concrete leavings are
washed away from the area around the wear ring and seal
ring when the nozzle is set to spray.
5–86 A820196_05_0704
Operation
" Mark the measured length on the hose with adhesive tape,
or similar.
5.10.2 Delivery Line There are a number of options for cleaning a delivery line. Some
Cleaning Methods of the factors affecting which cleaning method you use include
how the concrete pump has been used and what equipment you
have available.
On the next page, you will find a summary of delivery line

cleaning methods. The symbols used in the summary are
explained below:
Explanation of Symbols
The delivery line is connected to the concrete pump.
The leavings are pumped by the concrete pump out of
the hopper and onwards to the site of concrete place-
ment. Cleaning is from the hopper onwards to the site of
concrete placement.
The delivery line is connected to the concrete pump.

The leavings are sucked back by the concrete pump
from the site of concrete placement into the hopper.
Cleaning is backwards from the site of concrete place-
ment to the hopper.
The delivery line has been disconnected from the

concrete pump. The leavings are forced forwards from
the start of the delivery line to the site of concrete place-
ment using an external force (compressed air or water
under pressure). Cleaning is from the start of the deliv-
ery line to the site of concrete placement.
The delivery line has been disconnected from the

concrete pump. The leavings are forced backwards from
the the site of concrete placement to the start of the de-
livery line to using an external force (compressed air or
water under pressure). Cleaning is from backwards from
the site of concrete placement to the start of the delivery
line.
Recommended method of cleaning
Method of cleaning not recommended
A820196_05_0704 5–87
Operation
Prohibited method of cleaning
Method of cleaning not possible
Summary of Delivery Line Cleaning Methods
Leavings
from
Delivery line to
Method of
cleaning
Compressed air only with

no onwards de-
special
livery line con-
Water under pressure equipment
livery lline
nected to the
oncretee pump
mp
b
boom tip
i
Suction cleaning
om deli

with onwards
Boom
nted con
special
delivery line Water under pressure equipment
connected to the
mount
boom tip
Suction cleaning
Truck--m
Compressed air
Tr
Lateral outlet Water under pressure
Suction cleaning

special
ry linee
Riser Water under pressure equipment

nary delivery
Suction cleaning
de

special
Station
Downpipe Water under pressure equipment

S
Suction cleaning
5–88 A820196_05_0704
Operation
5.10.3 Delivery Line Suction To clean the delivery line using the “suction cleaning” method,
Cleaning perform the following steps:
Note
Suction cleaning is the simplest and least hazardous method of
cleaning the delivery line.
1. Pump the agitator hopper out until the concrete is at the level
of the top of the delivery cylinder tubes. Then switch the
pump off.
2. As shown in the diagram below, insert a water--soaked

wash--out sponge (cube) into the end hose outlet:
A820196_05_0704 77
Inserting a Water-Soaked Wash-Out Sponge
3. As shown in the diagram below, shift the placing boom into a

uniformly rising position. This makes it easier to pump the
concrete back as the concrete flows back under its own
weight.
A820196_05_0704 5–89
Operation
A820196_05_0704 78
Shifting the Placing Boom into a Uniformly Rising Position
4. Switch the pump to reverse pumping and then turn the pump
on. This will cause the concrete and wash-out sponge to be
pumped back through the delivery line.
5. As shown in the diagram below, tap on the delivery line with a

piece of hardwood (hammer handle) just ahead of the
cleaning eye during the washing out process.
Note
Tapping produces deep dull noises when there is concrete in the
delivery line. Tapping will yield high, clear sounds as soon as the
concrete and wash--out sponge have passed the point at which
you are tapping. Use only a hammer handle to tap on the
delivery line, as otherwise the pipe may be damaged.
5–90 A820196_05_0704
Operation
A820196_05_0704 79
Checking for the Wash-Out Sponge by Tapping on the Delivery Line with Hammer
Handle
6. Switch the pump off as soon as the wash-out sponge has

passed the point at which you are tapping.
A820196_05_0704 5–91
Operation
7. Open the wash--out port on the transfer tube, turn the

wash-out port lid around and close it again with the pin
pointing inwards.
A820196_05_0704 80
Trapping the Wash-Out Sponge By Turning the Wash-Out Port Lid Around
8. Switch the pump back over to reverse pumping. The

wash--out sponge will be trapped on the pin of the wash--out
port lid. Then switch the pump off.
9. Open the wash--out port lid and remove the wash--out

sponge.
10. Repeat the washing out procedure, as a single reverse

pumping pass of a wash--out sponge is not sufficient.
5–92 A820196_05_0704
Operation
5.10.4 Cleaning the Hopper, To clean the hopper, delivery cylinder and S-tube, perform the
Delivery Cylinder, and following steps:
S-Tube
Caution
In no event should you insert the water hose, the spray gun or
other objects through the grill into the hopper to spray out the
delivery cylinders. Such objects may be trapped by the transfer
tube as it switches over and become damaged. The objects may
be caused to fly about, thereby causing an injury to you or other
persons.
1. Drain off the leavings onto a suitable sized tarp (with

grommets for hoisting) beneath the hopper by performing the
following steps (refer to diagram below):
A. Place the tarp beneath the hopper.

B. Open the hopper flap beneath the hopper and let the
leavings flow out of the hopper.
C. Switch the pump over to reverse pumping. This pumps
the leavings out of the delivery cylinders into the hopper
and thus out of the hopper opening.
A820196_05_0704 81
Draining Off the Leavings Onto a tarp Beneath the Hopper
A820196_05_0704 5–93
Operation
Caution
Ensure to follow tarp manufacturer’s instructions and weight
limitation before you hoist the left over concrete.
– Hoist concrete as close to the ground as possible to prevent
damage to equipment and/or personal injury to personnel from
falling concrete.
2. Hoist away the concrete in the tarp.
A820196_05_0704 82
Hoisting the Concrete Away
3. As shown in the diagram below, spray out the S-tube and

delivery cylinder by performing the following steps:
A. Open the hinged elbow.
B. Allow the concrete pump to run slowly in reverse.
C. Spray the S-tube out carefully downwards from the

hinged elbow. Slowly insert the hose up to the marking as
you do this (mark the water hose using the tape marking
procedure).
5–94 A820196_05_0704
Operation
A820196_05_0704 83
Spray Out the S-Tube and Delivery Cylinder with the Concrete Pump Running
Slowly in Reverse
D. Hold the water hose in this position, introduced as far as

the marking, for several minutes, until only clean water
runs out. This will flush out the two delivery cylinders
alternately.
A820196_05_0704 84
Insert the Water Hose into the Transfer Tube as Far as the Marking
4. Carefully spray out the hopper using a hose.
5. Hose down all components that have come into contact with
concrete.
A820196_05_0704 5–95
Operation
5.10.5 Truck Superstructure Once the delivery line, hopper, delivery cylinders and transfer
and Post--Washing tube have been washed out, you must then rinse down
Operations thoroughly all parts of the machine that have come into contact
with concrete. Concrete that is not washed off immediately can
attack the paint, especially if aggressive concrete additives have
been used. Perform truck superstructure and post-washing
operations by completing the following steps:
Caution
The delivery line, water box, water tank and water pump must be
drained fully if there is a risk of freezing. The water box must
also be drained at normal temperatures during longer breaks in
pumping, e.g. overnight and at weekends, etc. Leave the water
outlet open afterwards.
Danger of explosion
Atomized preserving agents are highly explosive. Keep away
from all sources of ignition while spraying.
Danger of poisoning
Cleaning agents, solvents or preserving agents sprayed in air
can enter the lungs and cause serious health damage. You
should, therefore, always wear respiratory protection during this
work.
1. Clean all seals and the seal seats. Grease the seals before
replacing them.
2. Clean the remaining parts of the machine by rinsing down

with a water hose. Then spray the metal components with an
anticorrosion agent or release agent.
3. Clean and drain the water box daily.
5–96 A820196_05_0704
Operation
5.11 Teardown To teardown the machine after a concrete pour and prepare it for
travel, perform the following steps:
5.11.1 Boom folding sequence

Note
When the arm assembly is folding, the end hose cannot
automatically drop into the end hose catch brackets because of
the design of the 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
crank lever in the C hinge to compress the delivery line, adjacent
hydraulic cylinders, or other components. Retract the placing
boom carefully.
Caution
You must have folded arm 4 in fully before you fold arm 5 in fully,
otherwise the D hinge crank lever will press against the pipe
bend at the boom tip.
Therefore, only fold arm 5 in fully once you have folded arm 4 in
fully.
A820196_05_0704 5–97
Operation
Arm 5
A820196_05_0704 85
Folding arm 5
" Fold arm 5 in so that the boom tip is approximately 1 m

from the D hinge.
Arm 4
A820196_05_0704 86
Folding arm 4 in fully
" Fold arm 4 in fully until it rests against arm 3.
5–98 A820196_05_0704
Operation
Arm 5
A820196_05_0704 87
" Now fold arm 5 in fully until it rests against arm 4.
Arm 3
A820196_05_0704 88
A820196_05_0704 5–99
Operation
Arm 2
A820196_05_0704 89
Folding in arm 2 and catching the end hose
" Then fold in arm 2.

⇒ The end hose will automatically drop into the transport
latches.
Lowering the arm

assembly onto
the cradle
2.
1.
A820196_05_0704 90
Slewing and lowering the arm assembly
" Slew the arm assembly until it is in the storage position

and then lower it.
5–100 A820196_05_0704
Operation
Note
The arms must be fully retracted and lie on the support cradle
provided.
Check that the end hose is secured for transport.
" Set the toggle switch on the remote control back to the
“Support leg” position.
" Proceed to outriggers teardown section.
5.12 Folding Sequence Also read the “Travel” chapter and the “Unfolding the Boom”
when using section.
One--Side--Support
Caution
There must be no concrete in the delivery line along the arm as-
sembly when the arm assembly is being folded. The arm assem-
bly is designed for certain working positions while the pump is in
operation; these are described in the Operating Instructions.
However, when the arm assembly is being folded, the arm is
moved to positions which would place too heavy a load on the
arm assembly if the delivery line were to be full.

the boom. Fold the placing boom carefully.
You should further note that the end hose (depending on the ma-
chine’s equipment) is positioned loosely in the end hose brack-
ets and hangs down freely when the boom is being folded in and
out.
A820196_05_0704 5–101
Operation
Arm 5
A820196_05_0704 91
Folding arm 5
" Fold arm 5 in so that the boom tip is approximately 1 m

from the D hinge.
Arm 4
A820196_05_0704 92
5–102 A820196_05_0704
Operation
Arm 5
A820196_05_0704 93
" Now fold arm 5 in fully until it rests against arm 4.
Arm 3
A820196_05_0704 94
A820196_05_0704 5–103
Operation
Arm 2
A820196_05_0704 95
Folding in arm 2 and catching the end hose
" Then fold in arm 2.

⇒ The end hose will automatically drop into the transport
latches.
Arm assembly vertical
A820196_05_0704 96
" Raise the arm assembly to the vertical.
5–104 A820196_05_0704
Operation
2.
1.
A820196_05_0704 97
" Then slew the arm assembly to the rest position by the
shortest route and lower it onto the support cradle.
Note
The arms must be fully retracted and lie on the support cradle
provided.
Check that the end hose is secured for transport.
" Set the toggle switch on the remote control back to the
“Support leg” position.
" Proceed to outriggers teardown section.
5.12.1 Outriggers Teardown
Note
The same safety and operational rules apply for retracting the
outriggers as for extending them (refer to the “Outriggers Setup”
section on page 5–33).
A820196_05_0704 5–105
Operation
" As shown in the diagram below, unlock the outrigger legs

by performing the following steps:
A. Pull out pin (1).
2.
1.
A820196_05_0704 98
Outrigger snaplock -- Unlock the outrigger legs before you retract them or swing
them in.
" On the radio or cable remote control, move the horn/outrig-

ger/reset switch to the outrigger position.
" Raise and then retract (or swing in) the rear outriggers.
Caution
Only execute one outrigger at a time. Observe leveling bubble
and ensure that truck remains level as each outrigger is
positioned. Stability is jeopardized at a deviation from horizontal
of 3_ or more.
" Repeat above step for the front outriggers.
Note
The snaplocks lock the support legs again automatically as soon
as they have reached their fully retracted position.
" On the radio or cable remote control, move the horn/outrig-

ger/reset switch to the center position.
" Secure all the outrigger leg snaplocks with pins (provided).
5–106 A820196_05_0704
Operation
" Secure the end hose and the accessories against falling
from the truck.
" Confirm that the accumulator is depressurized by looking
at the accumulator pressure gauge.
5.12.2 Controls Teardown
" At radio remote control transmitter (or cable remote con-

trol), perform the following steps:
• Push in emergency stop button. This should depressurize the
hydraulic system by dumping the accumulator.
• Turn power switch to “off” position (radio only).
" If using a cable remote control, roll up cable and store

cable.
" Store radio remote control transmitter (or cable remote

control) in a protected location, preferably in the truck cab.
" Switch the power take-off (PTO) off by performing the fol-
lowing steps:
Caution
The following points must be complied with to prevent damage
when using power take-off gearboxes:
– The transmission must be in neutral when the power take-off
gearbox is switched on or off.
– If the engine was shut down during pumping operations and
your truck has a manual transmission, you must depress the
clutch before starting it up again.
A. If your vehicle has a manual transmission, perform these

steps:
• Push in clutch pedal (clutch disengaged).
• Place truck transmission in neutral
• Let clutch pedal out (clutch engaged).
B. If your vehicle has an automatic transmission, shift
selector from “D” (Drive) to”N” (Neutral).
C. Position concrete pump PTO switch (located on right side
of driver’s seat) to “DRIVE” position (PTO disengaged).
D. Verify that green “PUMP” light goes out.
A820196_05_0704 5–107
Operation
E. Release parking brake.

F. If your vehicle has an automatic transmission, shift
selector to “D” (Drive). Display indicates “1” signifying
that the truck transmission is in 1st gear.
5.13 Pumping Concrete To pump concrete with the Emergency Stroke Kit
With the Emergency (P/N A052763), perform the following steps:
Stroke Kit
Caution
THE EMERGENCY STROKE KIT SHOULD ONLY BE USED IN
AN EMERGENCY CONDITION. THE EMERGENCY STOP
(E-STOP) BUTTON DOES NOT WORK WHEN USING THE
EMERGENCY STROKE KIT.
1. Stop truck engine and verify that shift circuit pressure is at zero.
2. Disconnect pump harness from the following valves on the compact block:
• Stroke change--over valve (Y5)
• Stroke change--over valve (Y4)
• Accumulator dump valve (Y165)
3. Connect Emergency Stroke Kit wiring harness to three connections
disconnected in Step 2 and battery (refer to diagram below):
10 Amp Fuse
Red
Black
ON
12 to 24 Volt Toggle Switch
OFF
Transformer
Battery
Y5
Stroke
Y165 Change--Over
Accumulator Valve
Dump
Y4
Stroke
Change--Over
Valve A820196_05_0704 99
Emergency Stroke Kit (Connected Between Battery and Compact Block)
5–108 A820196_05_0704
Operation
4. Start truck engine.
5. Ensure that truck engine RPM is greater than 900 RPM.
6. Use toggle switch on Emergency Stroke Kit wiring harness to shift drive
cylinders at end of each stroke.
7. During an emergency condition or when job has been completed, stop truck
engine.
A820196_05_0704 5–109
Operation
5–110 A820196_05_0704
6 Maintenance
In this section 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.
We would like to emphasize that all prescribed checks, inspections and

preventative maintenance work must be conscientiously carried out.
Otherwise, we will refuse to accept any liability or to honor the warranty.
Should you ever be in any doubt, our Customer Support Group is always
ready to give you advice and assistance.
A820105_06_0501A 6–1
Maintenance
Lock Out — Tag Out Personnel servicing the unit should be protected from
Procedure unexpected start - ups. Use of the following procedures is
strongly recommended.
Lock Out - Tag Out Procedure:
1. Diesel Engine Powered Units

• Place all controls in the neutral or ’off’ position.
• Switch engine off and remove the key. The key must be kept by the
individual performing the work.
• Put a notice on the unit near the ignition switch stating ‘Under Repair – DO
NOT START.’ As shown in the following illustration:
2. Electric Powered Units

• Place all controls in the neutral or ‘off’ position.
• Turn off the main power supply to the pedestal control box.
• Disconnect the power cable from the pedestal control box.
• Put a notice on the main power supply and the pedestal control box stating
‘Under Repair - DO NOT START.’ As shown in the following illustration:
Tag Out Notice

FRONT BACK
DANGER DANGER
DO NOT REMOVE NO QUITE

THIS TAG. ESTA ETIQUETA.
UNDER REPAIR EN REPARACION
DO NOT START. NO ARRANCAR.
A800157 Rev. B
A820196_06_0704 01
Lock Out - Tag Out Notice (included in ship - away kit)
6–2 A820196_06_0704
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 section.
Note
Have the initial After Sales service after 100 hours of operation
carried out by a Putzmeister After Sales service engineer in
accordance with the enclosed inspection booklet. The machine
operator responsible for the machine should be present for this
service.
every ... hours of operation other

Assembly Action
daily 50 100 250 500 1000 intervals
Lubricate truck superstructure D weekly
Visual and function check on all safety

D
equipment
General Check threaded unions against torque

as required
table
Inspection by subject expert D annually
Visual inspection of electrical cabling D
Check hydraulic fluid level D
Drain off condensed water D
Visual check of the lines

D
(damage/leaks)
Hydraulic system
Full fluid change (after fluid analysis) D
Clean fluid sump D
Check hydraulic cylinder for tightness

monthly
(visual inspection)
Check contamination indicator on the

D
filters
Fluid filter Replace boom filter element as required
Replace intake filter element as required
Check water level D

Water tank and/or outrigger
(swing leg) water tank Clean out tank as required
A820105_06_0501A 6–3
Maintenance
every ... hours of operation other

Assembly Action
daily 50 100 250 500 1000 intervals
Full oil change splitter box D
Full oil change agitator gearbox D
Transmission Full oil change slewing gear

D annually
transmission
Condensed water slewing gear trans-

D
mission
Boom pedestal Check slewing ring bolts (if applicable) D
Wear check D
Transfer tube Check and adjust sealing gap D
Check tightening torque of bolts D
Coupling safety clips D

Delivery line
Check wall thickness D
Check threaded unions and securing

D
wire
Delivery piston
Check wear on delivery pistons weekly
Parts in contact with concrete Wear check D
Centralized lubrication system Check grease level D
Check oil level D
Full oil change D

Compressor
Clean air intake filter D
Check threaded unions D
Universally jointed shafts

Lubricate D
(in normal operating conditions)
Universally jointed shafts

Lubricate D
(in extreme operating conditions)
Truck engine
In accordance with the truck manufacturer’s maintenance specifications
Truck transmission
Check fuel level D
Outrigger (swing leg) diesel fuel Change water-particle filter as required
Clean out tank as required
6–4 A820196_06_0704
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 sections of the Operating
Instructions or in spare parts sheets.
Caution
You must always use bolts of the same size and grade when you
have to replace bolts. Bolts with adhesive in the locking threads
and self-locking nuts must always be replaced after removal.
The tables below give the maximum tightening torques Md in

Nm for a friction factor μtot. = 0.14, for a lightly - oiled or
lightly - greased thread.
Note
All tightening torques are multiplied by a factor of 1.1 for bolts
with cement in the thread.
A820105_06_0501A 6–5
Maintenance
Set screws - metric triangular thread DIN 13, Part 13

Dimensions Tightening torque Tightening torque
[mm] Md [Ft-Lb] Md [Nm]
M SW 8.8 10.9 12.9 8.8 10.9 12.9
M 4 7 2.22 3.26 3.77 3.0 4.4 5.1
M 5 8 4.37 6.44 7.4 5.9 8.7 10
M 6 10 7.4 11.1 13.3 10 15 18
M 8 13 18.5 26.6 31.8 25 36 43
M 10 17 36.3 53.3 62.2 49 72 84
M 12 19 62.9 92.5 107 85 125 145
M 14 22 99.9 148 174 135 200 235
M 16 24 155 229 270 210 310 365
M 18 27 222 318 370 300 430 500
10000900
M 20 30 315 451 525 425 610 710
SW = Width across flats M 22 32 429 607 710 580 820 960
X X = Grade
X.X G d 8 8.8,
8 10
10.9,
9 12
12.9
9 M 24 36 540 777 903 730 1050 1220
M 27 41 814 1147 1332 1100 1550 1800
M 30 46 1073 1554 1813 1450 2100 2450
Set screws - metric precision thread DIN 13, Part 13

Dimensions Tightening torque Tightening torque
[mm] Md [Ft - Lb] Md [Nm]
M SW 8.8 10.9 12.9 8.8 10.9 12.9
M 81 13 19.98 28.86 34 27 39 46
M 10 1.25 17 38.48 56.24 66.6 52 76 90
M 12 1.25 19 68.82 99.9 118.4 93 135 160
M 12 1.5 19 65.86 96.2 114.7 89 130 155
M 14 1.5 22 107.3 159.1 188.7 145 215 255
M 16 1.5 24 166.5 244.2 288.6 225 330 390
M 18 1.5 27 251.6 358.9 421.8 340 485 570
M 20 1.5 30 351.5 503.2 584.6 475 680 790
10000900
M 22 1.5 32 466.2 666 777 630 900 1050
SW = Width across flats M 24 2 36 592 851 999 800 1150 1350
X X = Grade
X.X G d 8 8.8,
8 10
10.9,
9 12
12.9
9 M 27 2 41 851 1221 1443 1150 1650 1950
M 30 2 46 1221 1739 2035 1650 2350 2750
6–6 A820196_06_0704
Maintenance
6.2.1 Flared Screwed Joint, Every time the joint has been undone, the union nut must be
Reassembly tightened securely, without the use of excessive force.
Flared screwed joints

External Md Md [Nm] External Md Md [Nm]
diameter/ [Ft - Lb] diameter/ [Ft - Lb]
Type Type
6 L 14.8 20 18 L 88.8 120
8 L 29.6 40 20 S 185 250
L 40.7 55 25 S 296 400
12
S 59.2 80 30 S 370 500
15 L 59.2 70 38 S 592 800
16 S 96.2 130
Note
Hold threaded union spigot fast against turning with wrench.
10400100
Tightening flared screwed joint
6.2.2 Profiled Ring Joint, Every time the joint has been undone, the union nut should be
Reassembly tightened again without excessive force to ensure that the joint is
tight.
A820105_06_0501A 6–7
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
Caution
Never mix hydraulic fluids with different characteristics (i.e. do
not mix biologically degradable hydraulic fluid with mineral
hydraulic fluids etc.).
Note
Use hydraulic fluid complying with the classification and
requirements standards specified in the lubricant
recommendation 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

hydraulic fluid remains in the system (in cylinders, pumps, lines,
etc).
6–8 A820196_06_0704
Maintenance
6.3.2 Oil for the Power The power take - off and agitator gearboxes (if equipped) are
Take - Off (PTO), Rotor filled with an API GL4 transmission oil of viscosity grade SAE 90,
and Agitator or synthetic oil, depending on the model used.
Gearboxes
Use only high quality transmission oil matching the exact
specification for model gearbox used on your truck.
6.3.3 Manual Lubrication Use a multipurpose lithium soap base grease for lubrication.
Marking in accordance with DIN 51502: K2K - 30, NLGI Class 2.
6.3.4 Centralized Fill the centralized lubrication system with a multipurpose lithium
Lubrication System soap base grease.
Marking in accordance with DIN 51502: K1K - 30, NLGI Class 1.
Low temperature We recommend grease marked K E 2G - 60 in accordance with

greases DIN 51502, NLGI Class 2 in a deviation from the lubricants table
if you wish to use a low temperature grease in the centralized
lubrication system under conditions of extreme cold.
6.3.5 Truck Engine Oil and The engine and the truck transmission are filled by the truck
Transmission Oil manufacturer. Maintenance only in accordance with the truck
manufacturer’s specifications.
6.3.6 Level of Contaminant Level of contaminant 18/14 in accordance with ISO 4406 is
specified for lubrication and the hydraulic system. You can find
the level of contaminant of the original filling from the report of
results on the machine card.
6.3.7 Lubricant Analysis Please consult the Putzmeister Customer Support Group should
you discover that the functioning of your machine is impaired
with one of the lubricants or hydraulic fluids used. We will carry
out a lubricant analysis to determine the cause.
6.3.8 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 store the barrels lying on their side and supported on

timber blocks, with the bung hole facing upwards.
A820105_06_0501A 6–9
Maintenance
You must carefully collect all functional fluids, e.g. used oil (includ-
ing biologically degradable oils), filters and auxiliary materials and
dispose 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.
6.4 Recommended We have listed the suitable lubricants in the tables on the next
Lubricants page. Putzmeister accepts no liability for the quality of the
lubricants listed or for changes in quality made by the lubricant
producer without changing the grade designation.
Note
Use only approved fluids when topping off fluid levels or carrying
out a full fluid changes.
Use only approved hydraulic fluid when topping off the hydraulic
fluid or carrying out a full fluid change if your machine was filled
with a synthetic ester.
Putzmeister accepts no liability for damages caused by mixing

fluids from different manufacturers.
It is recommended that you first consult the Putzmeister

Customer Support Group if you wish to use hydraulic fluids with
viscosity grades other than VG 68 at higher ambient
temperatures.
The proportion of residual fluid must not be greater than 2% after

a fluid change from mineral to biodegradable oi.. This means
that a flush filling with the full quantity of the new hydraulic fluid
must be carried out. In addition, for reasons of gasket
compatibility, a fluid change must be carried out no later than
6 months after the machine is commissioned. All filters must be
changed after 50 hours of operation, since deposits may be
dissolved and transported to the filters by the new fluid.
6–10 A820196_06_0704
Maintenance
Caution
The following points must be complied with in order to prevent
damage:
– Warm the machine up briefly if the hydraulic fluid temperature
is below 32_F (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
temperature of the hydraulic fluid (Multi-grade 68) has risen
above 50_F (10_C).
– The ideal temperature for the hydraulic fluid is between 104_F
to 158_F ( 40_C and 70_C).
Caution
Never mix hydraulic fluids of different types, ie do not mix bio
degradable hydraulic fluids with mineral hydraulic fluids etc.
6.4.1 Hydraulic Fluids

Initial filling
PMA Part
000171007
number
Classification HLP 46
Quantity 680L (179 Gal.)
Viscosity
DIN 51524
DIN EN ISO 6743
ISO VG 46
Type Mineral
Classification
DIN HLP - 46 51524/2
ISO HV46 6743
Requirement
DIN 51524 Part 2
ISO 6743
Particular
Multi-grade
characteristics
A820105_06_0501A 6–11
Maintenance
6.4.2 Oils and Greases

Centralized
Greasing
Engine oil Transmission oil* lubrication
(manual) system
Marking in acc.
HD HYP K2K - 30 K1K - 30
with DIN 51 502
Requirements API
API GL4 DIN 51 825 DIN 51 825
standard CH - 4/SJ
Characteristics mineral mineral, lithium soap
SAE 80
SAE SAE 90 NLGI Class
Viscosity grade, DIN NLGI Class 2
15W-40 DIN 51512 1
NLGI Class 51512 DIN 51818
DIN 51511 Standard DIN 51818
Winter
360001.00
Part number 000173.005 000101.006 — A026511
8
* The transmission oil for rotor pumps is listed separately.
6–12 A820196_06_0704
Maintenance Cards
In this section you will find the maintenance cards necessary for this
machine. The table of contents includes a summary of the maintenance
cards in numerical order, also there is an alphabetical summary in the
Index of key words under the entry for “Maintenance cards”.
A820196_MC_0704 613
614
Maintenance Card
00 - 001
Page 1 of 2
6.5 Visual Checks This maintenance card describes visual checks that you must carry out
before commencing any maintenance work. You will find the service
intervals in the maintenance summary at the start of this chapter.

Filter change
Hoses
No special tools required.
Warning
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.
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 function-
ing 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 cor-
rosion.
" Check that the electrical cables have no breaks.
" Check the insulation on the electrical cables.
WKUS00_001_0702EN 6 — 15
Maintenance Card
00 - 001
Page 2 of 2
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.
6 — 16 WKUS00_001_0702EN
Maintenance Card
01 - 014
Page 1 of 4
6.6 Slewing Gear This maintenance card describes how to check the oil level, drain off
Transmission the water of condensation and change the oil in the slewing gear
transmission. You will find the maintenance intervals in the
maintenance summary at the start of this chapter.
No further maintenance cards required.
Caution
Shut the machine down and dump the accumulator pressure
completely before you start working on the slewing gear transmission.
Note
The roller bearing on the transmission drive shaft has permanent
grease lubrication and does not usually need to be lubricated.
However, if it becomes necessary to replenish the grease packing
as a result of repairs to the transmission drive shaft, use roller
bearing grease 80, DIN 51825, worked penetration 220 = 250
(NLGI Class 3).
Carry out the full oil change with the machine at operating
temperature. This allows the transmission oil to flow out more easily.
It is recommended that the transmission be flushed out with a small
quantity of warm new oil to ensure that wear particles and
contamination are washed out in low ambient temperature conditions.
WKUS01_014_9907EN 6 — 17
Maintenance Card
01 - 014
Page 2 of 4
Slewing gear trans-

mission
1
4
5
8
WKUS01_014_9907EN 1
No 0 Designation
1 Transmission oil filler
2 Inspection glass
3 Transmission
4 Transmission oil drain plug
5 Brake oil filler
6 Screw plug for checking oil level
7 Brake
8 Brake oil drain plug
Checking oil level Check the oil level once a week when the machine is switched off, the
transmission is idle and the machine is standing on a level surface.
The oil level must not be lower than the lower edge of the inspection
glass or 1.18 inch (30 mm) below the top of the oil filler opening.
Condensate water Open the drain plug every 200 operating hours to drain the
condensate water out of the oil sump.
Full oil change The first full oil change must be carried out after 100 operating hours,
every further full oil change after 2000 operating hours, but at least
once a year.
6 — 18 WKUS01_014_9907EN
Maintenance Card
01 - 014
Page 3 of 4
Transmission
" Remove the transmission oil filler drain plug (1).
" Place a suitable container underneath to collect the transmis-

sion oil which flows out.
" Unscrew the bottom oil drain plug (4) of the transmission and
allow the transmission oil to drain out.
" Seal the oil drain opening again using the oil drain plug.
" Fill the transmission with transmission oil up to the upper edge
of the inspection glass via the oil filler (2).
" Seal the oil filler again using the oil drain plug.
Brake
" Remove the brake oil filler drain plug (5).
" Place a suitable container underneath to collect the transmis-

sion oil which flows out.
" Unscrew the brake oil drain plug (7) and allow the transmission
oil to flow out.
" Seal the oil drain opening again using the oil drain plug.
" Unscrew the screw plug (6) for checking the oil level.
" Fill the brake with transmission oil up to the lower edge of the
oil check screw plug via the oil filler.
" Seal the oil filler again using the oil drain plug.
WKUS01_014_9907EN 6 — 19
Maintenance Card
01 - 014
Page 4 of 4
6 — 20 WKUS01_014_9907EN
Maintenance Card
03 - 001
Page 1 of 6
6.7 Changing the This maintenance card describes how to carry out a full oil
Hydraulic Fluid change on the hydraulic system. You will find the service
intervals in the maintenance summary at the start of this section.

Function Checks
Filter Change
Hose Inspection and Replacement
Note
Cleanliness is of the greatest possible importance in the
maintenance 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.
WKUS03_001_0701EN 6–21
Maintenance Card
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 red monitoring ring 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.
Maintenance card: Filter Change
10401903
1 Red monitoring ring on vent filter
Warning
The accumulator pressure in pressurized systems must be
released. Confirm via gauge.
" Switch the drive engine off.
" Perform lock out - tag out procedure for diesel engine pow-
ered units.
Note
On some models, the hydraulic oil tank drain cock is located at
the front of the pedestal behind truck cab.
6–22 WKUS03_001_0701EN
Maintenance Card
03 - 001
Page 3 of 6
Changing the fluid
2
1
WKUS03_001_0701EN 2
Draining the hydraulic fluid

1 Drain cock for hydraulic fluid reservoir (passenger side)
2 Level indicator
You must make sure you collect the old hydraulic fluid and dis-
pose of it in accordance with the regulations. Biologically de-
gradable hydraulic fluids must also be disposed of separately
from other waste, just like mineral hydraulic fluids!
" Turn (counterclockwise) ON the drain cock for the hydrau-

lic fluid tank and drain the hydraulic fluid into a suitable
sized container.
" Open drain valve on suction filter and drain the hydraulic
fluid in filter housing.
" Remove clean out lid from tank.
" Wipe out inside of tank with a lint - free cloth. Wipe as far
into the tank as possible when doing this. You should also
remember that there may also be separate apertures in-
tended for tank cleaning.
WKUS03_001_0701EN 6–23
Maintenance Card
03 - 001
Page 4 of 6
" Disconnect hoses from tank and inspect for damage.

Maintenance card:Hose Inspection and Replacement
Note
Mark the hoses and their connection points for re - assembly.
10400300
Marking the hoses
" Wipe all hoses and fittings with a lint - free cloth.
" Remove all filter inserts.

Maintenance card: Filter Change
" Change all filters and refit the filter elements.
" Replace any defective hoses.

Maintenance card: Hose Inspection and Replacement
Dispose of the old filter inserts in accordance with the regula-
tions in force.
6–24 WKUS03_001_0701EN
Maintenance Card
03 - 001
Page 5 of 6
1
2
10300500
Filling the tank (Note: items may be located differently

depending on model)
1 Hydraulic oil tank filler tube with cap and strainer
2 Hydraulic oil tank vent filter
3 Oil level gauge
4 Clean out lid
" Fill tank with new fluid.
Note
Only fill the tank through the strainer 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 (Multigrade ISO VG68).
" Remove any dirt deposits from the oil cooler.
" Check all screwed joints and tighten where necessary.

Check all flared screwed joints.
" Check the electrical connections.
" Carry out all function checks.

Maintenance card: Function checks
WKUS03_001_0701EN 6–25
Maintenance Card
03 - 001
Page 6 of 6
" Bleed hydraulic system.
" Carry out several test runs.
" Fill hydraulic tank to “maximum” mark on gauge.
" Refit all the safety equipment, markings and notices you
have removed.
6–26 WKUS03_001_0701EN
Maintenance Card
03 - 002
Page 1 of 2
6.8 Function Checks This maintenance card describes the inspection of machine functions.
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.

Pressure gauge and connections for the tapping points shown in the
hydraulic circuit diagram
Note
It is highly recommended that only trained and qualified personnel
should carry out work on the hydraulic system. Notify the Putzmeister
Customer Support Group or your dealer/agent 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 read-
ing.
" Check the proper functioning of the pressure - relief valves in the
high pressure circuit and the pressure accumulator.
WKUS03_002_0702EN 6–27
Maintenance Card
03 - 002
Page 2 of 2
6–28 WKUS03_002_0702EN
Maintenance Card
03 - 006
Page 1 of 8
6.9 Performing This maintenance card describes how to check the accumulator
Maintenance on the pre - charge pressure. You should also take notice of any
Accumulator requirements valid in the country of use or specified by the
operator.
– Charging and Gauging Kit (Putzmeister #311803)

– Gas Valve Core Tool
– Spanner Wrenches
– Bladder Pull Rod
– Sockets - 27 mm, 36 mm
– Blunt Flathead Screwdriver
– Soft Faced Hammer
– Torque Wrenches
3
2
5
Charging and Gauging Kit

1 T-handle
2 Manual bleed valve
3 Check valve
4 Cap nut
5 Charging hose, including cap screw connections
WKUS03_006_0701EN 6–29
Maintenance Card
03 - 006
Page 2 of 8
Danger of explosion
USE ONLY DRY NITROGEN TO FILL THE ACCUMULATOR.
THERE IS A DANGER OF EXPLOSION IF COMPRESSED AIR,
OXYGEN OR OTHER GASES ARE USED.
Note
Check the accumulator pre - charge pressure once the hydraulic
fluid has warmed up to its operating temperature of 122_F
(50 _C) to 158_F (70 _C).
The setpoint value for the accumulator pre - charge pressure may
be found on the hydraulic schematic (item 120). The actual
value you measure may not be more than 15% less than the
setpoint value specified.
Warning
Adhere to the following safety regulations when performing
maintenance on the accumulator:
– The hydraulic accumulator is a pressurized vessel and only
qualified technicians should perform the necessary repairs.
– The fluid must always be drained completely from the
accumulator before performing any work.
6–30 WKUS03_006_0701EN
Maintenance Card
03 - 006
Page 3 of 8
15
16 1 14
13
2 12
11
10
3
4
5
6
7
8
9
WKUS03_006_0701EN 3
Accumulator
1 Protecting cap
2 O - ring
3 Gas valve insert
4 Bladder
5 Screw plug
6 Back - up ring
7 O - ring
8 O - ring
9 Transfer stud (3/4” hole)
10 Pressure gauge (0 - 250 Bar, mounted on boom rest)
11 Connection
12 Intermediate ring
13 Thrust ring
14 Union nut
15 Steel pipe
16 Mounting clamp
WKUS03_006_0701EN 6–31
Maintenance Card
03 - 006
Page 4 of 8
6.9.1 Checking To check accumulator pre-charge pressure, perform the

Accumulator following steps:
Pre-Charge Pressure
Note
The proper gas pre - charge pressure (1320 PSI or 90 bar) is set
at the factory. It is suggested that the pressure be rechecked
approximately 3 - 4 months after placing unit in service and every
12 months thereafter.
Warning
BEFORE CHECKING THE PRE - CHARGE PRESSURE, BE
SURE MACHINE IS SHUT DOWN AND ALL HYDRAULIC
PRESSURE AND FLUID IN ACCUMULATOR HAS BEEN
RELIEVED.
1. Unscrew valve protection cap (#1) and valve seal hex cap. Be
careful not to damage O - ring (#2) when removing cap.
2. To connect gauging unit to accumulator, perform the following
steps:
• Turn T−handle counterclockwise until resistance is felt.
• Close manual bleed valve, hand tight.
• Connect gauging unit to accumulator by screwing cap nut
onto gas valve, hand tight.
3. After gauging unit has been installed, turn T-handle clockwise
a maximum of 3 full turns from full counterclockwise position.
4. If gauge does not indicate 1320 PSI (90 bar), perform
appropriate procedure to increase or decrease accumulator
pressure:
By performing this procedure

If pressure reading is . . . Then . . .
...
Increase Increasing Accumulator
< 1320 PSI (90 bar)
pressure Pressure
Decrease Decreasing Accumulator
> 1320 PSI (90 bar)
pressure Pressure
5. If gauge indicates proper pre-charge pressure, remove

charging and gauging unit by performing the following steps:
6–32 WKUS03_006_0701EN
Maintenance Card
03 - 006
Page 5 of 8
• Turn T−handle counterclockwise until resistance is felt to

close gas valve.
• Open manual bleed valve to relieve pressure in gauging
unit.
• Disconnect gauging unit by unscrewing cap from gas
valve.
• Re−install valve seal hex cap and tighten to 20 lb. ft. (27
Nm).
• Re−install valve protection cap, hand tight.
6.9.2 Decreasing To decrease pressure in accumulator, perform the following

Accumulator Pressure steps:
1. Install charging and gauging unit as per Steps 1 - 3 of

“Checking Accumulator Pre-Charge Pressure” procedure on
page 6–32.
2. Carefully open manual bleed valve, allowing gas pre - charge

pressure to release slowly.
3. Monitor gauge until desired gas pressure is reached.
4. Close manual bleed valve and allow pressure to stabilize.
5. After 5 - 10 minutes, recheck pressure and adjust accordingly.
6. When correct pressure is reached, remove charging and

gauging unit by performing the following steps:
close gas valve.
unit.
• Disconnect gauging unit by unscrewing cap from gas
valve.
Nm).
WKUS03_006_0701EN 6–33
Maintenance Card
03 - 006
Page 6 of 8
6.9.3 Increasing To increase accumulator pressure to specified pressure (per

Accumulator Pressure hydraulic schematic), perform the following steps:
1. Install charging and gauging unit as per Steps 1 - 3 of

“Checking Accumulator Pre-Charge Pressure” procedure on
page 6–32.
2. Allow 5 - 10 minutes for the gas temperature to stabilize.
3. Turn T-handle clockwise until gauge begins to deflect, then

turn it another full turn.
Danger of explosion
ONLY USE DRY NITROGEN GAS. NEVER USE OXYGEN OR
AIR BECAUSE IT COULD CAUSE AN EXPLOSION.
Caution
It is recommended that the commercial nitrogen bottle be
equipped with a regulator to adjust pressure. Full pressure may
damage the gauge.
4. Connect charging hose to cap screw adapter and to nitrogen

bottle discharge.
5. Purge air in hose so you charge only with nitrogen.
6. Open shut - off valve on nitrogen bottle and slowly fill

accumulator with dry nitrogen gas. Charging too quickly may
damage the accumulator.
Note
The gauge on the gauging unit registers the line pressure and
not necessarily the accumulator pressure while charging.
7. Check accumulator pressure as follows:

• Close shut−off valve on nitrogen bottle.
• Allow gas temperature and pressure to stabilize.
• Check accumulator pressure.
8. Fill or release pressure as required until required pressure is
reached.
6–34 WKUS03_006_0701EN
Maintenance Card
03 - 006
Page 7 of 8
9. When correct pressure is reached, remove nitrogen bottle

and gauging unit by performing the following steps:
• Close shut−off valve on nitrogen bottle.
close gas valve.
unit.
• Disconnect charging hose and remove gauging unit from
accumulator.
Nm).
6.9.4 Replacing It is highly recommended that you take the accumulator to a

Accumulator Bladder qualified hydraulic repair shop or contact the Putzmeister
Customer Support Group Service Hotline for assistance.
Telephone: (800) 890 - 0269
Fax: (262) 884 - 725
6.9.5 Bladder kit A bladder kit with seal set is available from Putzmeister
(PN AT311945) for replacement. To purchase contact the
Putzmeister Parts Hotline
Telephone: (800) 890 - 0269
Fax: (262) 884 - 7259
WKUS03_006_0701EN 4
Bladder kit with seal set
WKUS03_006_0701EN 6–35
Maintenance Card
03 - 006
Page 8 of 8
6–36 WKUS03_006_0701EN
Maintenance Card
04 - 002
Page 1 of 4
6.10 Hose Inspection and This maintenance card describes how to check and replace the
Replacement hydraulic hoses. You will find the maintenance intervals in the
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.
WKUS04_002_0608EN 637
Maintenance Card
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.
External Type Max torque Max. torque External Type Max. torque Max. torque
diameter Md [Ft - Lb] Md [Nm] diameter Md [Ft - Lb] Md [Nm]
6 L 15 20 18 L 88.5 120
8 L 29 40 20 S 184 250
L 41 55 25 S 295 400
12
S 59 80 30 S 369 500
15 L 52 70 38 S 590 800
16 S 96 130
638 WKUS04_002_0608EN
Maintenance Card
04 - 002
Page 3 of 4
Replacing hoses The procedure for replacing hoses is as follows:
" Shut down the machine and secure against unauthorized start-
ing.
" Fully dump any (residual) pressure in the hydraulic system.
Caution
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.
Note
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.
Catch escaping fluid in a container and dispose of in an environmen-
tally friendly manner.
WKUS04_002_0608EN 639
Maintenance Card
04 - 002
Page 4 of 4
640 WKUS04_002_0608EN
Maintenance Card
04 - 005
Page 1 of 2
6.11 Vacuum Meter This maintenance card describes how to replace the vacuum meter
Replacement and how to remove the packing piece. You will find the service
intervals in the maintenance summary at the start of this section.
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.
WKUS04_005_0701EN 6 — 41
Maintenance Card
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.
6 — 42 WKUS04_005_0701EN
Maintenance Card
04 - 012
Page 1 of 6
6.12 Changing the Suction This maintenance card describes how to change the suction filter
Filter Element element. You will find the maintenance intervals in the maintenance
summary at the start of this chapter.
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

hydraulic systems. Prevent any type of dirt from entering the system.
Even small particles of dirt may cause valves to be scored, pumps
to seize and throttle and control bores to become blocked.
Hydraulic fluid barrels must stand for some time before the fluid is
removed from them. Never roll the barrels to where you will be
drawing 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.
WKUS04_012_0701EN 643
Maintenance Card
04 - 012
Page 2 of 6
Caution
Filter elements available on the market may have too low a flow rate.
It is therefore recommended, that you 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.
Dispose of used filter elements in accordance with the relevant regu-
lations.
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.
Caution
The pressure accumulated in pressurized systems must be dumped.
" Perform ‘Lock out - Tag out’ procedure for diesel engine pow-
ered units (start of this chapter).
644 WKUS04_012_0701EN
Maintenance Card
04 - 012
Page 3 of 6
Changing
1. 3
2.
4.
3.
WKUS04_012_0701EN 1
No. 0 Designation
1 Lid
2 Hexagon nut
3 Plug
4 Drain cock
Note
Above illustration is for reference only to show how to remove the
filter lid to access the filter element. The filter configuration for your
machine may be different.
" 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.
WKUS04_012_0701EN 645
Maintenance Card
04 - 012
Page 4 of 6
" 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.].
WKUS04_012_0701EN 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.
Any hydraulic fluid which escapes must be disposed of in accordance
with the relevant regulations.
646 WKUS04_012_0701EN
Maintenance Card
04 - 012
Page 5 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 re-
verse of the procedure for removing a filter element.
WKUS04_012_0701EN 647
Maintenance Card
04 - 012
Page 6 of 6
648 WKUS04_012_0701EN
Maintenance Card
04 - 013
Page 1 of 6
6.13 Changing the This maintenance card describes how to change the pressure filter
Pressure Filter element. You will find the maintenance intervals in the maintenance
Element summary at the start of this chapter.
Note
Cleanliness is of the utmost importance in the maintenance of
hydraulic systems. Prevent any type of dirt from entering the system.
Even small particles of dirt may cause valves to be scored, pumps
to seize and throttle and control bores to become blocked.
Hydraulic fluid barrels must stand for some time before the fluid is
removed from them. Never roll the barrels to where you will be
drawing 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.
WKUS04_013_0701EN 649
Maintenance Card
04 - 013
Page 2 of 6
Caution
Filter elements available on the market may have too low a flow rate.
It is therefore recommended, that you 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.
lations.
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.
Caution
The pressure accumulated in pressurized systems must be dumped.
" Perform ‘Lock out - Tag out’ procedure for diesel engine pow-
ered units (start of this chapter).
650 WKUS04_013_0701EN
Maintenance Card
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.
WKUS04_013_0701EN 1
Checking and changing the pressure filter
" Bring the machine up to operating temperature (> 122°F/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.
WKUS04_013_0701EN 651
Maintenance Card
04 - 013
Page 4 of 6
Changing
Tighten to:
35−40 ft. lbs. (50 Nm)
WKUS04_013_0701EN 2
No. 0 Designation
1 Filter element
2 Filter housing
Caution
652 WKUS04_013_0701EN
Maintenance Card
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).
" Tighten filter housing using hex nut on bottom to 35 - 40 ft. lbs.
(50 Nm).
Note
Check the level of the contamination indicator. Always refit the
protective lid on the contamination indicator each time this is
checked.
WKUS04_013_0701EN 653
Maintenance Card
04 - 013
Page 6 of 6
654 WKUS04_013_0701EN
Maintenance Card
04 - 014
Page 1 of 4
6.14 Changing the This maintenance card describes how to change the ventilation filter
Ventilation Filter element.
Element
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 655
Maintenance Card
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)
656 WK04_014_0308EN
Maintenance Card
04 - 014
Page 3 of 4
" Undo the screw cap from the filter housing.
" Remove the filter element from the filter housing.
lations.
Caution
" Clean the filter housing and the inside of the screw cap with a
clean cloth.
" When fitted, reset the 3 - stage maintenance indicator by turning

the rotary knob anti - clockwise in the direction of the arrow.
å The 3−stage maintenance indicator jumps back to its origi−
nal 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 657
Maintenance Card
04 - 014
Page 4 of 4
658 WK04_014_0308EN
Maintenance Card
06 - 047
Page 1 of 8
6.15 Delivery Piston This maintenance card describes how to replace the delivery pistons on
Replacement 2 - KEP a 2 - KEP system. In the 2 - KEP (piston end - of - travel positioning)
System system, there is a ball valve fitted in the stroke correction line of each
drive cylinder. You will find the maintenance intervals in the maintenance
summary at the start of this chapter.
Note
Damage to the delivery pistons must be rectified without delay.
Putzmeister accepts no warranty claims for damage to the machine
resulting from failure to properly observe the maintenance regulations.
Warning
Secure the working area. Place warning notices on blocked control and
setting devices.
You will have to start up and shut down the machine a number of times
when replacing the delivery pistons. The operations necessary for this
task are described below and must be carried out conscientiously.
Execute all machine functions from the cable remote control.
Shutting down the Proceed as follows to shut down the machine:

machine
" Switch off the engine.
" Press the EMERGENCY SHUT - DOWN button.
" Dump the pressures completely.
WKUS06_047_0701EN 659
Maintenance Card
06 - 047
Page 2 of 8
Warning
Dump the accumulator pressure completely in systems with pressure
accumulators.
Starting up the ma- Proceed as follows to start up the machine:

chine
" Unlock the EMERGENCY SHUT - DOWN button and sound the
horn.
" Switch the engine on.
Caution
Do not switch the pump on until you are called upon to do so.
Blocking the drive cyl- You must block each associated drive cylinder in the end position before
inders in the end posi- you are able to remove the delivery pistons.
tion
Note
To lock the drive cylinders in the end position “with minimum wear”, set
the pumping rate below 50% and the engine speed to approximately half
the maximum value.
Closing the stroke Each drive cylinder stroke correction line has a ball valve (KEP) that is
correction lines fitted open (markings parallel to the line) ex works and is locked against
turning. It is necessary to close the stroke correction line to the drive
cylinder from which you are removing the delivery piston using the ball
valve.
660 WKUS06_047_0701EN
Maintenance Card
06 - 047
Page 3 of 8
20202301
The factory presets the ball valve (KEP) in the open state
20202302
1 As - fitted position secured against rotation

2 Rotate position
" Undo the bolt on the handle and remove the handle.
" Lift up the guide washer and refit it rotated through 90_.
WKUS06_047_0701EN 661
Maintenance Card
06 - 047
Page 4 of 8
WKUS06_047_0701EN 2
Ball valve (KEP) when closed
" Replace the handle.
" Press the Change - over switch when the concrete pump is running
and hold it down until the concrete pump switches off.
" Close the ball valve once the two drive cylinders have stopped
moving.
Note
Just after you have closed the ball valve, there is a possibility that one of
the drive cylinders may move again briefly until both drive cylinders are
finally in mechanical end position.
" Now switch the concrete pump off.
" Then you can release the Change - over switch.
662 WKUS06_047_0701EN
Maintenance Card
06 - 047
Page 5 of 8
Piston replacement When replacing pistons you may work with the remote control on the
platform.
1 2 3 2 4
5
10600301
1 Piston rod flange

2 Fastening bolts
3 Securing wire
4 Delivery piston
5 Spacer flange
" Shut the machine down.
" Drain the water from the water box and remove the cover.
" Start the machine up.
" Move the drive piston of the delivery piston to be removed to its
end position. The spacer flange must be fully visible in the water
box.
" Remove the securing wire from the fastening bolts.
WKUS06_047_0701EN 663
Maintenance Card
06 - 047
Page 6 of 8
10600701
1 Fastening bolts
" Unscrew the fastening bolts for the spacer flange from the drive
piston rod and from the delivery piston and remove the spacer
flange.
" Slowly bring the drive piston rod up to the delivery piston.
1
10600800
1 Pulling bolts
" Remove the protective caps from the two pulling bolts and bolt the
delivery piston to the drive piston using the two pulling bolts.
" Pull the delivery piston completely out of the delivery cylinder.
664 WKUS06_047_0701EN
Maintenance Card
06 - 047
Page 7 of 8
" Undo the threaded joint and remove the old delivery piston.
" Thoroughly clean the delivery piston edge at the end of the water
box.
Caution
Do not use any hard objects or caustic cleaning agents to clean the
delivery cylinder. These could damage the chrome layer.
" Grease a new delivery piston heavily with acid - free grease (e.g.
Vaseline).
" Bolt the new delivery piston to the drive cylinder using the two pull-
ing bolts.
" Slowly advance the drive piston rod and push the new delivery pis-
ton carefully into the delivery cylinder. The pulling bolts must re-
main freely accessible.
" Unscrew the pulling bolts and replace the protective caps.
" Retract the drive piston rod sufficiently for the spacer flange to fit
between the delivery piston and the drive piston.
" Insert the spacer flange and fasten all the bolts.
" Tighten the bolts to the specified tightening torques and secure
them with a stainless steel wire.
WKUS06_047_0701EN 665
Maintenance Card
06 - 047
Page 8 of 8
Opening the stroke

correction lines
20202301
Open the ball valve (KEP) and secure it against rotation
" Open the ball valve (KEP) when delivery piston replacement is
completed.
" Replace the guide washer so that it is blocked in position, fit the
handle and bolt it down.
Caution
The ball valves must be opened and secured by the guide washers when
the machine is being operated.
The pump may not be able to change the stroke over any longer if the
ball valve is closed.
" Then carry out a test run.
Note
Replace the second delivery piston in the same way.
666 WKUS06_047_0701EN
Maintenance Card
07 - 001
Page 1 of 2
6.16 Lubricating the This maintenance card describes the lubrication of all lubrication
S - Transfer Tube points on the transfer tube if you do not have a centralized lubrication
system or system is inoperable. You will find the maintenance
intervals in the maintenance summary at the start of this chapter.

Grease gun
Note
Use a grease with the marking K2K in accordance with DIN 51502,
NLGI Class 2.
Lubrication intervals You should grease the lubrication points one to three times daily,
unless a different interval is specified. You should apply the grease
until you can see it escaping.
30300103
Transfer tube and plunger cylinder lubrication diagram
WKUS07_001_0702EN 667
Maintenance Card
07 - 001
Page 2 of 2
668 WKUS07_001_0702EN
Maintenance Card
07 - 011
Page 1 of 20
6.17 S - Transfer Tube This maintenance card describes how to replace the S - transfer tube
Replacement and its wear parts. You will find the maintenance intervals in the

Measuring the wall thickness
You should request the special fitting instructions from us if you have
a spectacle wear plate made from a special material (e.g. hard metal,
hard cast iron, ceramics).
Torques The tightening torques are listed in the “General tightening torques”
section at the start of the Maintenance chapter. Torques differing from
these are specified in the spare parts sheets.
Caution
Shut down the machine before commencing work and secure it
against unauthorized or accidental starting. Dump the accumulator
pressure.
Use only suitable lifting equipment for lifting components.
Note
The wear parts must be replaced if visual inspection reveals wear or
if there is insufficient pressure build - up in the delivery line.
WKUS07_011_0701EN 6–69
Maintenance Card
07 - 011
Page 2 of 20
S - transfer tube
variants
1 2
WKUS07_011_0701EN 1
No. 0 Designation
1 S - transfer tube S2318 LS P9 (X= 238.5/90 mm)
2 S - transfer tube S2318 (w/90 mm shaft)
Note
Whatever variant of S - transfer tube fitted, the recommended
procedure for dismantling is as described below.
6–70 WKUS07_011_0701EN
Maintenance Card
07 - 011
Page 3 of 20
Overview
3
2
4 5
1 6
10
7 8 9 8
30300101
No. 0 Designation
1 Plunger cylinder
2 Retaining plate
3 Retaining plate fastening bolts
4 Clamping bolts with nuts
5 Switch lever
6 Hexagon nut on the switching shaft
7 Fastening bolt for flanged bearing (10)
8 B fastening bolts for spectacle wear plate
9 A fastening bolts for spectacle wear plate
10 Flanged bearing
11 (not shown) Two jacking bolts
WKUS07_011_0701EN 6–71
Maintenance Card
07 - 011
Page 4 of 20
Removing the transfer The S - transfer tube is mounted in the transfer tube bearing in the
tube bearing rear wall of the hopper.
" Open the grille on the hopper and secure it.
" Attach suitable lifting gear to the S - transfer tube.
" Remove the lubrication lines from the transfer tube bearing.
1
3 4
2
10800901
No. 0 Designation
1 Fastening bolts
2 Jacking bores with jacking thread
3 Transfer tube bearing
4 Hinged elbow
" Swing the hinged elbow (4) to one side.
" Remove the two fastening bolts (1) for the transfer tube bear-
ing (3) and force the bearing out by screwing the two jacking
bolts supplied into the jacking bores.
" Check the seal rings and O - rings in the transfer tube bearing
for wear and replace as required.
6–72 WKUS07_011_0701EN
Maintenance Card
07 - 011
Page 5 of 20
Transfer tube bearing

seal set
10801000
Bend the seal rings to make installation easier
Caution
The mounting position for the seal set in the transfer tube bearing can
be found in the accompanying spare parts sheet.
" Grease the new seal set and fit it as illustrated on the spare
parts sheet.
Note
Clean the transfer tube bearing before refitting and grease the seals.
Check the lubricant bores, in particular, for proper functioning. This is
done by connecting the lubrication lines and forcing lubricant through
the apertures.
Removing the switch- The switching shaft of the S - transfer tube is mounted in the switching
ing shaft bearing shaft bearing (flanged bearing) in the front wall of the hopper.
(flanged bearing)
" Remove any lubrication lines on the retaining plate and flanged
bearing.
WKUS07_011_0701EN 6–73
Maintenance Card
07 - 011
Page 6 of 20
10300700
Unbolting the retaining plate
" Undo the fastening bolts on the retaining plate and remove the
retaining plate. (You will have to replace the locking plates on
the fastening bolts with new ones on reassembly.)
Collect the escaping hydraulic fluid in a suitable container and dis-
pose of it in accordance with the disposal regulations applicable for
your region.
" If necessary for space reasons, disconnect the hydraulic hoses

leading to the plunger cylinders at the bulkhead unions. Then
close off the hydraulic lines with plugs.
10300800
Removing the plunger cylinders
6–74 WKUS07_011_0701EN
Maintenance Card
07 - 011
Page 7 of 20
Note
The plunger cylinders can be pushed back as illustrated. It is,
however, also possible to screw a bolt into the jacking bores for the
ball cups and to push the plunger cylinders out with the ball cups.
" Push back the pistons in the plunger cylinders and remove the
plunger cylinders with the hydraulic hoses.
" Undo the hexagon nut on the switching shaft and remove the
spacer ring.
10700200
Loosening the clamping bolts
" Undo the clamping bolts on the switch lever.
" Spread the switch lever apart by screwing the two jacking bolts
supplied into the two bores.
" Withdraw the switch lever from the switching shaft.
WKUS07_011_0701EN 6–75
Maintenance Card
07 - 011
Page 8 of 20
1
2
10700300
No. 0 Designation
1 Fastening bolt
2 Jacking bores (2 diagonally opposed)
3 Flanged bearing
" Unscrew the fastening bolt (1) from the flanged bearing (3).
" Force the flanged bearing off by screwing the two jacking bolts
supplied into the jacking bores (2).
" Check the seal rings and O - rings in the flanged bearing for
wear and replace these as required.
Flanged bearing
seal set
10700400
Removing the retaining ring
" Remove the retaining ring.
6–76 WKUS07_011_0701EN
Maintenance Card
07 - 011
Page 9 of 20
10700500
Removing the old seal set
" Remove the old seal set. It may be necessary to cut the
seal rings to do this.
10700600
Fitting the new seal set
Caution
The mounting position for the seal set in the flanged bearing can be
found in the accompanying spare parts sheet.
" Grease the new seal set and fit it as illustrated on the spare
parts sheet.
Note
Clean the flanged bearing before refitting and grease the seals.
Check the sleeve for wear and replace if necessary.
WKUS07_011_0701EN 6–77
Maintenance Card
07 - 011
Page 10 of 20
Removing the spec-

tacle wear plate
10700800
Pushing the S - transfer tube to one side
" Push the S - transfer tube away from the spectacle wear plate.
1 2 1
30300102
No. 0 Designation
1 B fastening bolts
2 A fastening bolts
" Undo the 8 fastening bolts and remove the spectacle wear plate
from the transition liner.
6–78 WKUS07_011_0701EN
Maintenance Card
07 - 011
Page 11 of 20
Removing the S - Replace the S - transfer tube if the wall thickness has fallen below the
transfer tube minimum.
Maintenance card: Measuring the wall thickness
Note
If there is no need to replace the S - transfer tube or the wear sleeve
in the S - transfer tube outlet, you may skip this operation and
continue at the “Fitting the spectacle wear plate” operation.
10801200
Removing the agitator shaft
" Remove the agitator shaft.
10700900
Lifting out the S - transfer tube
" Unbolt the scratch bar from the bottom of the S - transfer tube.
" Push the S - transfer tube forwards until the transfer tube outlet
is free.
WKUS07_011_0701EN 6–79
Maintenance Card
07 - 011
Page 12 of 20
" Lift the S - transfer tube outlet opening first upwards and out.
Note
If you wish only to replace the wear sleeve, you must also carry out
the operations on the next page and only then fit the S - transfer tube
again.
If you are replacing the complete S - transfer tube, fit the new tube in
the reverse sequence to disassembly.
" Fit the new S - transfer tube.
Replacing the The wear sleeve can be replaced without the requirement to replace
wear sleeve in the S - the S - transfer tube if the wear sleeve is heavily worn. The S - transfer
transfer tube tube must be removed to do this.
Caution
There is a risk of burning during heating and fitting of the new wear
sleeve. Use suitable protective equipment.
Caution
Do not damage the transfer tube when cutting off the wear sleeve.
10701001
1 Wear sleeve
6–80 WKUS07_011_0701EN
Maintenance Card
07 - 011
Page 13 of 20
" Carefully cut the wear sleeve at two opposing points using an
angle grinder and remove the two parts.
Note
The wear sleeve is chrome - plated and therefore must not be heated
locally or at too great a temperature.
" Heat the new wear sleeve uniformly to a maximum temperature

of 284_F (140_C).
" Place the heated wear sleeve over the transfer tube outlet and
allow the wear sleeve to cool.
" Replace the S - transfer tube.
Fitting the spectacle Screw two short threaded rods into the two upper threaded bores in
wear plate the spectacle wear plate and insert these into the upper holes in the
hopper wall to make positioning of the spectacle wear plate easier
during fitting.
" Check the O - rings in the intermediate rings on which the spec-
tacle wear plate is placed.
" Clean the mounting surfaces and grease them with a multipur-
pose grease.
Caution
The spectacle wear plate rests only against the O - rings of the
intermediate rings. There is a small clearance between the spectacle
wear plate and the hopper wall. The B fastening bolts (outer fastening
bolts) should therefore initially only be tightened finger - tight, as
otherwise the spectacle wear plate may be broken.
WKUS07_011_0701EN 6–81
Maintenance Card
07 - 011
Page 14 of 20
10801300
Fitting the spectacle wear plate
" Fit the new spectacle wear plate.
1
max. 0.020 in.
max. 0.5 mm
ÉÉÉÉÉÉ
ÉÉÉÉÉÉ
ÉÉÉÉÉÉ
ÉÉÉÉÉÉ
2
30800101
No. 0 Designation
1 Spectacle wear plate
2 Intermediate ring
6–82 WKUS07_011_0701EN
Maintenance Card
07 - 011
Page 15 of 20
" Put the new spectacle wear plate in place and fasten it with the
B fastening bolts (outer fastening bolts). Tighten these only to
finger - tightness initially.
" Bolt down the spectacle wear plate with the A fastening bolts
(top and bottom) and tighten them to the appropriate tightening
torque.
" Tighten the B fastening bolts to the tightening torques given in

the accompanying spare parts sheet. The spectacle wear plate
may only be distorted by a maximum of 0.020 inch (0.5 mm)
when the bolts are tightened.
Replacing the Replace the wear ring in the event of heavy visible wear, if concrete is
wear ring leaking or if there is inadequate pressure build - up in the delivery line.
2
1
10701002
No. 0 Designation
1 Thrust ring
2 Wear ring
" Remove the old wear ring and the thrust ring.
" Fit a new thrust ring and a new wear ring in the S - transfer tube.
WKUS07_011_0701EN 6–83
Maintenance Card
07 - 011
Page 16 of 20
Fitting the transfer

tube bearing
10800900
Transfer tube bearing
Note
Pay attention to the location of the lubrication openings when fitting
the transfer tube bearing.
" Fit the transfer tube bearing on the S - transfer tube outlet and
bolt it securely.
Wear sleeve and col-

lared washer
10701100
Locating the collared washer
" Bend the tab on the collared washer downwards.
" Place the collared washer on the flanged bearing housing so

that the tab is located in the bore, thereby securing the washer
against rotation.
" Insert the wear sleeve into the flanged bearing housing.
6–84 WKUS07_011_0701EN
Maintenance Card
07 - 011
Page 17 of 20
Note
Note the location of the lubrication bores when fitting the flanged
bearing.
" Grease the inside of the wear sleeve with “Anti - Seize AS 450
Assembly Paste” or an equivalent assembly grease.
" Locate the complete flanged bearing on the switching shaft and
bolt it tight.
" Locate the wear sleeve on the switch lever.
Mounting the
switch lever
WKUS07_011_0701EN 2
Aligning the switch lever
Note
The topmost tooth of the switching shaft is slightly flattened and may
be used as a marker.
" Grease the teeth on the switch lever and the switching shaft
with “Anti - Seize AS 450 Assembly Paste” or an equivalent as-
sembly grease.
" Fit the switching lever in such a way that the flattened tooth on
the switching shaft is located in the notch in the switching lever
and the wear sleeve is form - fitted on the switching lever.
WKUS07_011_0701EN 6–85
Maintenance Card
07 - 011
Page 18 of 20
1 2 3
30300101
No. 0 Designation
1 Spacer ring
2 Switching shaft
3 Hexagon nut
" Fit the spacer ring (1) on the switching shaft (2) and screw the
hexagon nut (3) onto the switching shaft.
Note
The gap (clearance between wear ring and transfer tube) must be set
to ensure that the transfer tube switches correctly.
6–86 WKUS07_011_0701EN
Maintenance Card
07 - 011
Page 19 of 20
7 6 5
1 2 3 4
WKUS07_011_0701EN 3
No. 0 Designation
1 Spectacle wear plate
2 Wear ring
3 Transfer tube
4 Thrust ring
5 Hexagon nut
6 Gap between wear ring and transfer tube
7 Wear ring is flat against the spectacle wear plate
" First tighten the hexagon nut (5) on the switching shaft so that
the wear ring (2) lies flat (7) against the spectacle wear
plate (1).
" Then slowly tighten the hexagon nut (5) further until the transfer
tube (3) lies against the wear ring (2).
å This will prestress the thrust ring(4).
" Then undo the hexagon nut (5) on the switching shaft by
about ¾ of a turn. This will automatically set the gap re-
quired (6) between the transfer tube (3) and the wear ring (2).
å A small gap is created between the wear ring and the
transfer tube.
å The wear ring is pressed against the spectacle wear plate
by the lightly prestressed thrust ring.
WKUS07_011_0701EN 6–87
Maintenance Card
07 - 011
Page 20 of 20
Note
Use only new nuts for the clamping bolts.
" Insert the two clamping bolts in the switch lever and fit new
nuts. Tighten the clamping bolts in accordance with the “Gener-
al tightening torques” table.
" Further assembly is carried out in the reverse sequence to dis-

assembly.
Note
The hydraulic lines must be bled after reassembly. Do this by starting
up the pump slowly and switching the transfer tube across slowly a
few times.
6–88 WKUS07_011_0701EN
Maintenance Card
10 - 007
Page 1 of 6
6.18 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
with S - transfer tube) maintenance summary at the start of this chapter.

Wall thickness measuring device
Note
Delivery lines are subject to constant wear. Measurement of the wall
thickness is particularly important before starting on large jobs.
You will obtain reliable results for your measurements if you carry out
the test with the measuring device recommended by Putzmeister.
Danger of explosion
The delivery line can burst once it reaches a high delivery pressure if
the wall thickness of the delivery line has decreased below the mini-
mum 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 lining of high wear resisting pipes
may flake off the inside of the pipe. The pipe can burst at points that
have suffered heavy wear.
WKUS10_007_0608EN 689
Maintenance Card
10 - 007
Page 2 of 6
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 pipes is shown in the graph
below.
Bends Uniform wear can be achieved by regularly rotating the bends

through 180°. The wear on the external radius of a bend is greater
than that on the internal radius or on straight pipes. You should,
therefore, take special care when measuring the wall thickness of
the external radius of a bend.
The minimum wall thickness for bends is shown in the graph below.
11000200
Rotate delivery pipes and bends regularly
690 WKUS10_007_0608EN
Maintenance Card
10 - 007
Page 3 of 6
S - transfer tube The minimum wall thickness for the S - transfer tube depends on the
maximum possible operating pressure. Furthermore, the fact that the
transfer tube is subject to greater stress at the point at which the
torque is applied (switching shaft - transfer tube) must be taken into
consideration.
WKUS10_007_0608EN 4
X = Area of heavy loading
Operating pressure up Guide value for wall thickness

to 1885.5 psi (130 bar) [mm]
Area A 0.315 - 0.394 in. [8 - 10 mm]

Area B 0.236 - 0.315 in. [6 - 8 mm]
Note
We should draw your attention to the fact that the transfer tube is
subject to varying loading as a result of the dynamic loading during
pumping. There is no general method for calculating the minimum
wall thickness for this loading, which depends on the individual
circumstances, and so the transfer tube can also burst at an
operating pressure which is assumed still to be permissible.
You should also note that the operating pressure can rise to the
maximum pressure in the event of a blockage, and in this case the
wall thickness may no longer be adequate.
If the operating pressure is higher than 1885.5 psi (130 bar), consult
the Putzmeister Customer Support Group what the minimum wall
thickness is.
WKUS10_007_0608EN 691
Maintenance Card
10 - 007
Page 4 of 6
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
circumference of the delivery pipes.
The minimum wall thickness is shown in the graph below.
Caution
Pipes and bends 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 an operating
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
minimum wall thickness for this loading, which depends on the
individual circumstances, and so the delivery line can also burst at an
operating pressure which is assumed still to be permissible.
Furthermore, the operating pressure can rise to 1233 psi (85 bar) in
the event of blockages, meaning that the wall thickness will no longer
be adequate and the delivery line will burst.
692 WKUS10_007_0608EN
Maintenance Card
10 - 007
Page 5 of 6
Graph Minimum wall thickness as a function of operating pressure

Psi (Bar)
3625 (250)
3480 (240)
3335 (230)
3191 (220)
3045 (210)
2900 (200)
2755 (190)
2610 (180)
2465 (170)
2320 (160)
2175 (150)
2030 (140)
101885 (130) 1
1740 (120)
1595 (110)
1450 (100)
1305 (90)
2
1160 (80)
1015 (70)
870 (60)
725 (50)
580 (40)
435 (30)
290 (20)
145 (10)
0
Inch 0.0 .020 .039 .059 .079 .098 .118 .138 .157 .177 .197 .217 .236 .256 .276 .295 .236 .335 .354 .374 .394
(mm) (0.5) (1.5) (2.5) (3.5) (4.5) (5.5) (6.5) (7.5) (8.5) (9.5)
(1.0) (2.0) (3.0) (4.0) (5.0) (6.0) (7.0) (8.0) (9.0) (10.0)
1 High pressure
2 Maximum delivery pressure
WKUS10_007_0608EN 693
Maintenance Card
10 - 007
Page 6 of 6
694 WKUS10_007_0608EN
Maintenance Card
20 - 055
Page 1 of 2
6.19 Lubricating the This maintenance card describes the lubrication of all lubrication
placing boom points on the placing boom if you do not have a centralized
(M43/47 RZ) lubrication system or system becomes inoperable. You will find the
maintenance intervals in the maintenance summary at the start of this
chapter.

Grease gun
Note
NLGI Class 2.
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.
WKUS20_055_0704en 1
Lubrication diagram for M 46/47 RZ placing boom
WKUS20_055_0704en 695
Maintenance Card
20 - 055
Page 2 of 2
696 WKUS20_055_0704en
Maintenance Card
21 - 040
Page 1 of 2
6.20 Lubricating the boom This maintenance card describes the lubrication of all lubrication
pedestal (TRDI 140) points on the boom pedestal if you do not have a centralized
lubrication system or system becomes inoperable. You will find the
maintenance intervals in the maintenance summary at the start of this
chapter.

Grease gun
Note
NLGI Class 2.
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.
WKUS21_040_0704EN 1
Lubrication diagram for TRDI 140 boom pedestal
WKUS21_040_0704EN 6 — 97
Maintenance card
21 - 040
Page 2 of 2
6 — 98 WKUS21_040_0704EN
Maintenance Card
21 - 001
Page 1 of 2
6.21 Checking the This maintenance card describes how to check and replace the
Connecting Bolts On connecting bolts on the ball - bearing slewing ring. You will find the
the Ball - Bearing service intervals in the maintenance summary at the start of this
Slewing Ring section.

Torque wrench
Note
The connecting bolts on the ball - bearing slewing ring must be
checked every 500 hours of operation, but at least once a year.
Caution
This inspection may only be carried out by an expert.
2
2
12101401
1 Loose connecting bolt

2 Connecting bolts that must also be replaced
" Tap the connecting bolts with a hammer.
Note
A dull ring means that the bolt is loose. A clear ring means that the
bolt is tight.
WKUS21_001_0211EN 699
Maintenance Card
21 - 001
Page 2 of 2
Caution
Do not tighten loose bolts, but replace them with new ones. In
addition, the two bolts to the left and the two bolts to the right of the
loose bolt must be replaced. Use only original spare parts as listed in
the table below.
" Replace the loose bolts and the two neighbouring bolts on each
side.
" Oil the thread and the head bearing surface with SAE 30 oil and
tighten the replacement bolts in accordance with the torque
table given below.
Tightening torques
Size Part number (AN)
Ft. Lbs [Nm]
M 12 066560005 81 [110]
042568005
M 24 553 [750]
042969002
043133002
043134001
M 24 649 [880]
043135000
231468000
222770008
M 30 1291 [1750]
223045004
6100 WKUS21_001_0211EN
Maintenance Card
24 - 003
Page 1 of 6
6.22 Outrigger (Swing This maintenance card describes how to replace the diesel fuel
Leg) Diesel Fuel and filter for the right hand side outrigger (swing leg) diesel fuel
Transfer Tank Fuel transfer tank. You will find the maintenance intervals in the
and Filter maintenance summary at the start of this section.
Replacement

Filter wrench.
Warning
Safety decal affixed to swing leg on top near fuel cap
Preparation The following tasks must be carried out before changing the
diesel fuel filter:
" Turn the machine off (if running).
" Perform Lock Out - Tag Out Procedure.
" Secure the system against unauthorized starting – if you

have any keyed switches, remove the key and disconnect
the supply voltage.
" Secure your working area and fix notices to the blocked
controls and setting devices.
" Have a suitable sized container ready for draining diesel

fuel.
" Have oil dry or drop cloth handy to soak - up spilled diesel
fuel.
WKUS24_003_0612EN 6–101
Maintenance Card
24 - 003
Page 2 of 6
6.22.1 Draining the Fuel If diesel fuel in outrigger diesel fuel tank is contaminated with
Tank and Changing water or other particles, drain and replace the diesel fuel and
the fuel fuel filter by performing the following steps.
filter
Caution
Contaminated diesel fuel may cause damage to diesel engine or
diesel powered equipment. Replace contaminated diesel fuel
before use.
6
7
2 3 4
1
Outrigger diesel fuel tank hose and nozzle

1 Fuel hose nozzle
2 Fuel hose
3 Ball valve
4 Water - particle fuel filter
5 Truck fuel tank
6 Fuel level gauge
7 Outrigger diesel fuel tank (right “passenger” side)
You must make sure you collect the old fuel filter and dispose of
it in accordance with the regulations. Contaminated diesel fuel
must also be disposed of separately from other waste.
6–102 WKUS24_003_0612EN
Maintenance Card
24 - 003
Page 3 of 6
" Open ball valve (3).
" Remove fuel hose nozzle (1) from its holding device.
" Squeeze trigger on nozzle and drain diesel fuel into a suit-
able size container.
" Return nozzle to its holding device.
" Use filter wrench to loosen the fuel filter (4).
" Drain any remaining diesel fuel from filter into container.
" Close the ball valve.
" Remove fuel filter.
" Wipe out all the openings with a lint - free cloth.
" Coat new filter gasket with oil.
" Install new fuel filter onto base.
" Hand tighten 3/4 to 1 full turn after gasket contacts base.
" Clean out tank using fresh diesel fuel or solvent.
" Properly dispose of the used diesel fuel and filter.
Dispose of the old fuel filter in accordance with the regulations in
force.
WKUS24_003_0612EN 6–103
Maintenance Card
24 - 003
Page 4 of 6
6.22.2 Refilling the Fuel Tank
Filling the tank

8 Fuel tank cap
" Remove fuel tank cap (8).
" Fill fuel tank (7) up to full mark on fuel level gauge (6) with
clean diesel fuel.
" Open ball valve to fill filter with clean diesel fuel.
" Remove nozzle from its holding device and place in truck
fuel tank (5) or container. Squeeze trigger on nozzle until a
steady stream of diesel fuel comes out (all air is bled out).
" Check for leaks.
" Return nozzle to its holding device.
" Close ball valve.
" Re - tighten filter if necessary.
" Replace any defective fuel hoses or clamps.
have removed.
6–104 WKUS24_003_0612EN
Maintenance Card
24 - 004
Page 1 of 8
6.23 Cleaning the This maintenance card describes how to clean the left hand side
Outrigger (Swing Leg) outrigger (swing leg) water tank. The swing leg and components
Water Tank used may differ depending on model (e.g., ball valves, caps,
hoses etc.). You will find the service intervals in the maintenance
summary at the start of this section.
Warning
Safety decal affixed to swing leg on top near water cap
Caution
The auxiliary water tank on your machine may or may not be
connected. Ensure tank is connected before use.
WKUS24_004_0612EN 6–105
Maintenance Card
24 - 004
Page 2 of 8
Preparation The following tasks must be carried out before cleaning the
auxiliary water tank:
Caution
Ensure to read the safety regulations and complete the
operations for setting up the machine before setting out the
machine outriggers. The machine outriggers may only be used
under the following conditions:
– the pump drive engine is running;
– the power take - off is engaged (i.e., the machine is set to
pumping operations);
– the “Outrigger” function has been selected at the remote con-
trol or on the control block.
It is absolutely forbidden to move the outriggers manually
(mechanically).
12101600
Do not move the hydraulic operated support legs

manually
" As shown in the diagram below, unlock the outrigger legs

by performing the following steps:
A. Pull out spring/locking pin (1).

6–106 WKUS24_004_0612EN
Maintenance Card
24 - 004
Page 3 of 8
Or
2
1
Outrigger snaplock - You must unlock the outrigger legs before you are able to extend them or swing
them out.
Note
Extendable support legs are automatically locked by the sna-
plock once the support leg is fully extended.
Once the legs are locked, replace the spring/locking pin. The
snaplock cannot be opened unintentionally and the support leg
remains locked in the end position.
The snaplock has no function once swing - out support legs have
been swung out. Do not replace the spring pin; in this way the
supports will be locked automatically when they are swung back.
Before driving off, make sure that all the snaplocks are secured
by a spring/locking pin.
" On cable or radio remote control, place boom/horn/outrig-

ger/reset switch in outrigger position.
Note
Refer to swing out, and lowering support pad in Operation
section for more detailed instructions.
" Swing out left rear support leg far enough to access clean
out lids.
" Lower support pad.
" Turn the machine off (if running).
WKUS24_004_0612EN 6–107
Maintenance Card
24 - 004
Page 4 of 8
" Perform Lock Out - Tag Out Procedure.
" Secure the system against unauthorized starting – if you

have any keyed switches, remove the key and disconnect
the supply voltage.
" Secure your working area and fix notices to the blocked
controls and setting devices.
Draining the auxiliary If water in outrigger auxiliary water tank is contaminated with
water tank rust, minerals or other debris, drain and clean the auxiliary water
tank by performing the following steps.
1
4
2 5
Outrigger (swing leg) auxiliary water tank (may differ depending on model)
1 Water tank cap
2 Level gauge
3 Water tank
4 Drain cock
5 Hose fitting
Note
For machines with disconnected tanks, the pipe port located on
inside of swing leg is plugged with a cap plug. For machines with
connected tanks, a ball valve is installed in place of plug.
6–108 WKUS24_004_0612EN
Maintenance Card
24 - 004
Page 5 of 8
" Connect hose to hose fitting (5).
" Open drain cock (4).
" Allow water to completely drain from water tank (3)
Cleaning the water To clean the inside of the water tank, perform the following
tank steps:
1
3
3 6
5
4
8
7
Swing leg as viewed from passenger side

1 Cap
2 Drain cock, or ball valve
3 Cleaning lid assembly
4 Cleaning lid
5 Clamping cross
6 O - ring
7 Socket head cap screw
8 Gasket
" Remove each of the cleaning lid assemblies (3) by:
" Removing the socket cap head screw (7) and gasket (8)
retaining the cleaning lid (4) and remove the clamping
cross (5) and O - ring (6) from tank.
WKUS24_004_0612EN 6–109
Maintenance Card
24 - 004
Page 6 of 8
Danger of fire
Do not use gasoline or other flammable liquids to clean out tank.
Fumes inside tank may ignite from sparks or other ignition
source and cause fire resulting in personal injury and/or equip-
ment damage.
" Clean out inside of tank using rags or non - flammable sol-
vent.
" Inspect O - ring and gasket, replace if necessary.
" Install O - ring onto cleaning lid.
" Insert socket head cap screw into gasket and cleaning lid
and thread into clamping cross.
" Insert clamping cross into hole of tank.
" Tighten socket head cap screw until cleaning lid is sealed
against tank.
" Repeat above steps for remaining cleaning lids.
" Properly dispose of dirty rags and solvent.
Filling the water tank To fill the auxiliary water tank, perform the following steps:
Filling the tank

1 Water tank cap
" Remove water tank cap (1).
6–110 WKUS24_004_0612EN
Maintenance Card
24 - 004
Page 7 of 8
" Fill water tank up to the half full mark on level gauge with
clean water.
" Check for leaks around cleaning lids. Retighten cap screw
if necessary.
Note
If leak persists, drain tank and recheck O - ring and gasket.
Replace if necessary.
" Replace any defective hoses or clamps.
" Fill water tank up to the full mark on level gauge.
have removed.
WKUS24_004_0612EN 6–111
Maintenance Card
24 - 004
Page 8 of 8
6–112 WKUS24_004_0612EN
Maintenance Card
24 - 005
Page 1 of 4
6.24 Centralized The centralized lubrication system fitted to your machine

Lubrication System functions automatically, i.e. the machine is lubricated at fixed
programmed intervals.
6.24.1 Filling the lubricant If the lubricant reservoir is empty, the indicator lamp will flash to
reservoir a rhythm of 0.25 seconds on - 0.25 seconds off.
Note
If the lubricant level falls below the mark during the course of a
lubrication procedure, the lubrication procedure is still
completed. Only then does the centralized lubrication system
report a fault.
WKUS24_005_0612EN 2
No. 0 Designation
1 Lubricant reservoir
2 Filler nipple
Note
In many cases the filler nipple of the lubricant reservoir is
extended with a hose and fastened to the truck superstructure
so that the lubricant reservoir can be filled more easily.
" Connect a grease gun to the filler nipple (2) on the lubri-
cant reservoir (1).
" Fill the lubricant reservoir (1) with grease.
WKUS24_005_0612EN 6–87
Maintenance Card
24 - 005
Page 2 of 4
6.24.2 Fault display The indicator lamp will flash if there is a fault in the centralized
lubrication system. The flash interval indicates the nature of the
fault.
Note
When the pump is switched on, the indicator lamps light up for
approximately 2 seconds and the system is tested. The
lubrication motors will run for a fraction of a second. The
indicator lamps will go out after 2 seconds if the system is in
order. A flashing indicator lamp indicates one of the conditions
described below.
1s 1s 1s 1s 1s
3 4
2
o.k.
5
1 M
WKUS24_005_0612EN 3
No. 0 Meaning
1 Indicator lamp Off
2 Indicator lamp On
3 Duration of the flash interval
4 Self - test after pump switched on
5 Fault in the drive motor or supply line
6 Lubricant reservoir empty
7 Fault in the lubrication circuit
Lubrication in progress
8 A fault has been acknowledged (see “toggle switch”
on the control panel in the steps)
6–88 WKUS24_005_0612EN
Maintenance Card
24 - 005
Page 3 of 4
6.24.3 Rectifying the fault Indicator lamps 1 and 2 indicate possible faults in the centralised
lubrication system.
1 2
WKUS24_005_0612EN 4
Note
When you switch off the pump or acknowledge a fault, the
indicator lamp goes out. When the pump is switched back on,
the indicator lamp will flash again indicating that a fault is
present.
" Rectify the fault in the centralized lubrication system.
" Press the toggle switch in the direction of the lubrication

circuit which had the fault (symbol) for more than 2 sec-
onds.
WKUS24_005_0612EN 6–89
Maintenance Card
24 - 005
Page 4 of 4
6.24.4 Additional lubrication You can cause an additional lubrication cycle to run if your
procedure machine is to be run under particularly heavy loading.
Note
An additional lubrication procedure is only possible if there is no
fault present.
" Press the toggle switch in the direction of the flashing indi-
cator lamp for less than 1 second.
å The indicator lamp stops flashing when the pump is
switched on.
å If the pump is switched off, the indicator lamp stops
flashing and lights up continuously, and the selected lu−
brication circuit is lubricated.
" Press the toggle switch in the direction of the lubrication

circuit you require (symbol) for more than 2 seconds.
å The indicator lamp lights up. The lubrication circuit se−
lected is lubricated. The interval time is reset to zero.
6–90 WKUS24_005_0612EN
Maintenance Card
25 - 001
Page 1 of 8
6.25 Replacing the This maintenance card describes how to replace the delivery line
Delivery Line and its seals. You will find the maintenance intervals in the

Measuring the wall thickness

4 mm feeler gauge
General The delivery line is subdivided into two sections:

- Boom delivery line
- Pump - boom delivery line.
These comprise:
- bends;
- straight pipes of uniform length;
- adapter pipes (straight pipes manufactured individually for
each arm package in order to fit the delivery line to the arm
lengths).
Wall thickness Measure the wall thickness of the delivery line to determine
which pipe sections 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. The delivery line is matched to the arm
length concerned by means of the adapter pipes. The length of
the pump - boom delivery line is also adapted by means of
adapter pipes.
WKUS25_001_0701EN 6–117
Maintenance Card
25 - 001
Page 2 of 8
Adapter pipe length

plate
2 1
3 Dia. Nom. 5
Putzmeister Inc.
Racine Operation
1733 90th Street L1 mm V1 mm 6
Sturtevant, WI 53177
L1.1 mm V2 mm
V L2 mm V3 mm
L2.1 mm V4 mm
L3 mm V5 mm
L3.1 mm V6 mm
4
L L4 mm V7 mm
7
L4.1 mm V8 mm
L5 mm V9 mm
L5.1 mmV10 mm
8
A 8 0 0 0 0 1 R e v. A
1 First adapter pipe on A arm (L1)

2 Second adapter pipe on A arm (L1.1)
3 First adapter pipe on B arm (L2)
4 Second adapter pipe on B arm (L2.1), etc.
5 First pipe in pump - deck delivery line (V1)
6 Second pipe in pump - deck delivery line (V2), etc.
7 V8 and V9 are adapter pipes for lateral outlets
8 V10 is always the riser pipe
Ordering The length of the adapter pipes differs according to the machine
and boom. For re - ordering purposes, you should take the
lengths and location of all the adapter pipes on your machine
from the adapter pipes plate next to the rating plate or from the
following spare parts sheets:
- Boom delivery line: Spare parts sheet group 25.0
- Deck/Pump - boom delivery line: Spare parts sheet group 25.3
6–118 WKUS25_001_0701EN
Maintenance Card
25 - 001
Page 3 of 8
The adapter pipe lengths 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 machine’s stability will have to be
recalculated and checked and approved by an authorized
inspector.
Untensioned The boom delivery line must be fitted with the arm assembly fully
assembly relieved of tension:
- the arm assembly is not under tension in the transport position
if each arm is lying freely on the rest provided for this purpose;
- the arm assembly is not under tension when unfolded if each
arm is supported.
WKUS25_001_0701EN 6–119
Maintenance Card
25 - 001
Page 4 of 8
Caution
If the tension on the arm package is not fully relieved during
assembly, 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 causing the end hose to swing
and strike out during pumping operations.
Clearance A clearance of 0.16 in. (4 mm) must be maintained between the

delivery pipes over the whole of the delivery line, so that the
welding neck rings can butt against the couplings without play.
This clearance is achieved either:
- automatically, through the use of a C seal (triple - lip seal), or
- manually, by adjustment, using a feeler gauge.
Seal C seals (triple - lip seals) are used where the delivery line runs in
a straight line and there is no rotational movement. The 0.16 in.
(4 mm) clearance is created automatically.
Caution
No triple- lip seals (C seals) may be used in the pivot joints in the
pipe bends.
A seals are used:

- if the delivery line does not run in a straight line;
- in the pivot joints; and
- at the assembly coupling at the tip of the boom.
The spacing of 0.16 in. (4 mm) must be set using the feeler
gauge.
6–120 WKUS25_001_0701EN
Maintenance Card
25 - 001
Page 5 of 8
Coupling Couplings with lever closures must be secured with a spring clip.
11000800
Securing couplings with lever closures
Couplings with a threaded closure are closed using self - locking

nuts. These nuts may not be re - used, but must be replaced
each time the coupling is fitted.
Fitting an A seal
0.16 in.
4 mm
Set the spacing with the feeler gauge
" Push the A seal over the fixed delivery line pipe.
" Lay the pipe to be attached in the pipe bracket and push it
up to the fixed pipe.
" Set the clearance of 0.16 in. (4 mm) between the pipes
using a feeler gauge.
WKUS25_001_0701EN 6–121
Maintenance Card
25 - 001
Page 6 of 8
" Fix the pipe to be attached in the pipe brackets.
" Push the A seal over the two weld - on rings.
" Fit the coupling and secure it.
Caution
No triple- lip seals (C seals) may be used in the pivot joints.
Fitting a C seal
4 mm 0.16 in.
The spacing is created automatically by the ring seal
" Push the C seal over the welded - on ring of the fixed deliv-
ery line pipe.
" Lay the pipe to be attached in the pipe bracket and push it
up to the fixed pipe.
" Push the pipe to be attached as far as the stop in the ring
seal.
" Fix the pipe to be attached in the pipe brackets.
" Fit the coupling and secure it.
6–122 WKUS25_001_0701EN
Maintenance Card
25 - 001
Page 7 of 8
Boom delivery line The starting points for laying the pipe on the boom are the pivot
points.
" Grease all couplings and seals well internally before as-
sembly.
Note
Refer to the “Recommended Lubricants” section at the start of
this chapter for an appropriate grease to use.
" Install the bends in the fitting couplings at the pivot points.
" Align the bends such that the straight pipes can be con-
nected without tension.
" Fix the bends.
" Install the fixed length delivery pipes.
" Install the adapter pipes last.
Pump - boom The pressure pipe is the starting point for assembly.
delivery line
Note
You should use only high - pressure pipes when replacing these
delivery line pipes.
Only C seals (triple - lip seals) are used throughout the
pump - boom delivery line.
" Grease all couplings and seals well internally before as-
sembly.
Note
Refer to the “Recommended Lubricants” section for an
appropriate grease to use.
" Fit the reducer pipe to the pressure pipe with a clamp cou-
pling. The clamp coupling must be capable of rotating with
the pressure pipe. The reducer pipe, which must be lo-
cated in a vibration absorber, may not turn either.
" Fit the boom connection pipes as far as the bend on the
riser pipe.
WKUS25_001_0701EN 6–123
Maintenance Card
25 - 001
Page 8 of 8
6–124 WKUS25_001_0701EN
7 Troubleshooting Guide
The previous sections of this manual dealt with the various

aspects of operation, preventative maintenance, adjustments,
and component replacement. This troubleshooting section will
assist you in recognizing and recovering from conditions that
cause equipment malfunctions.
Note
Please refer to the hydraulic and electrical schematics included
with this manual for specific reference to items and components.
A820196_07_0704 7–1
Troubleshooting Guide
7.1 Concrete Pump This section describes the possible causes of defects which may
affect the concrete pump and how to rectify them. The numbers
in parentheses are the item numbers on the hydraulic schematic.
The delivery pistons do not start
Cause Remedy
Pump not switched on With truck transmission in neutral and parking brake on, start truck
engine and engage concrete pump PTO. Verify that green PTO
light illuminates and place in correct pumping gear.
Lack of fluid in the Top up hydraulic fluid.

hydraulic system
No accumulator pressure On older machines, close accumulator dump cock (121).

(
(see ttestt reading
di ffor
119 Pressure gauge (250 bar) for accumulator (located on rear boom rest)
required value) 120 Accumulator (6.0L)
121 Accumulator relief valve
120
119
119
On newer machines, verify that hopper grate is closed and then

manually push solenoid-operated accumulator dump valve (184)
to see if accumulator pressurizes. If accumulator pressurizes
(when dump valve is pressed), problem is in the dump valve or its
circuitry.
181
119
184 120
119 Pressure gauge for accumulator 181 Shut - off valve with 5 mm Orifice
120 Accumulator 184 Safety cut - out for accumulator 24V
Vacuum meter (136) in the Vacuum filter (140) dirty. Replace filter element (141), clean
red zone magnetic rod, observe maintenance intervals.
7–2 A820196_07_0704
The delivery pistons do not start
Cause Remedy
Hydraulic fluid too cold Allow hydraulic fluid to warm up by idling.
Main hydraulic system Increase delivery rate regulation by:

pump (127) not engaged (1) Using electric volume control switch (211), or
for operation (2) Closing manual volume control valve (125)
Delivery piston blocked in Press reverse pumping switch or stroke change switch.
th end
the d position
iti
10600100
Engine speed too low. The Increase engine speed.

main pump does not
engage.
Pump has insufficient output
Cause Remedy
Main hydraulic system Increase delivery rate regulation by:

pump (127) not fully (1) Using electric volume control switch (211), or
engaged (2) Closing manual volume control valve (125)
A820196_07_0704 7–3
Pump is not running
Cause Remedy
Lack of fluid, machine Top up hydraulic fluid.

switches off automatically
Stroke change valve Press stroke change valve manual operation button (103a) a
(103a) sticks as a result of number of times, switch the pump over to reverse pumping for 2 -
fine dirt or defect 3 strokes. Check solenoid coils and their connections.
103a Stroke change - over switch control valve 24V
106 Main connection block
108 Reverse control valve
119 Pressure gauge for accumulator
120 Accumulator (6.0L)
125 Output regulator
142 Screw - in throttle M6
181 Shut - off valve
120
183 Automatic volume control
184 Safety cut - out for accumulator 24V
196 Push - Over - Valve (POV) NG6; 24V
211 Motorized volume regulation 24V
119 181
121
184
103a
196
125
106 211
108
142 183
7–4 A820196_07_0704
Pump does not switch over
Cause Remedy
Too little hydraulic fluid Top up hydraulic fluid.
Fuse blown Replace fuse.
Stepping relay in the Operate stroke change function. Verify that LED on the stroke
switch cabinet defective change module illuminates during cycle. If LED does not
illuminate, check stepping relay.
Stroke change valve Press stroke change valve manual operation button (103a) a
(103a) sticks as a result of number of times, switch the pump over to reverse pumping for 2 -
fine dirt or defect 3 strokes. Check solenoid coils and their connections.
106 Main connection block
181 Shut - off valve 120
119 181
121
184
103a
196
125
106 211
108
142 183
A820196_07_0704 7–5
Transfer tube does not switch or gets stuck
Cause Remedy
Insufficient accumulator On older machines, close accumulator dump valve (121).

pressure, accumulator
l t
119 Pressure gauge (250 bar) for accumulator (located on rear boom rest)
circuit not pressurized 120 Accumulator (6.0L)
(see test reading for 121 Accumulator relief valve
required value),
change-over pressure is
too low, or accumulator 120
119
dump valve (184) is open.
119
On newer machines, verify that hopper grate is closed and then

manually push solenoid-operated accumulator dump valve (184)
to see if accumulator pressurizes. If accumulator pressurizes
(when dump valve is pressed), problem is in the dump valve or its
circuitry.
181
119
184 120
119 Pressure gauge for accumulator 181 Shut - off valve with 5 mm Orifice
120 Accumulator 184 Safety cut - out for accumulator 24V
Accumulations of Remove by repeated change-over and reverse pumping, if

aggregate in the range necessary, open hopper and clean. Request concrete complying
through which the transfer with the standard. Set transfer tube hard/soft shift valve (181) to
tube swings, deposits in “hard shift” position (i.e., open).
the hopper
7–6 A820196_07_0704
Accumulator empties too quickly or no pressure
Cause Remedy
Hopper grate is open or Verify that hopper grate is closed and then manually push
solenoid-operated dump solenoid-operated accumulator dump valve (184) to see if
valve (184) is not accumulator pressurizes. If accumulator pressurizes (when dump
operating properly valve is pressed), problem is in the dump valve or its circuitry.
Hydraulic fluid is getting too hot
Cause Remedy
Too little cooling water in Top up the water.

th water
the t b box att hi
high
h
output
10600200
Cooling water too hot Replace with fresh water.
Too little fluid in the Top up hydraulic fluid.

hydraulic system
Pump is running in the Reduce pump delivery speed or ask for better concrete
maximum pressure range (composition).
because of poor concrete
and high delivery rate
Constantly at maximum Increase pipe size, eg from 4” (DN 100) to 5” (DN 125).
pressure in long - distance
delivery
A820196_07_0704 7–7
Hydraulic fluid is getting too hot
Cause Remedy
Overpressure as a result Remove blockage (by switching the pump over from delivery to
of a blockage reverse pumping a number of times).
10600100
Radiator (132) dirty, Switch on.

radiator fan not running Clean.
Check voltage and ground contact of thermocouple 131°F(55°C)
(not on front - mounted radiator).
7.2 Placing Boom This section describes the possible causes of defects which may
affect the boom and how to rectify them.
Caution
Only carry out maintenance and repair work on the placing boom
if the placing boom is retracted or properly supported, the engine
is switched off and the support legs are secured.
12000401
Supporting the boom
7–8 A820196_07_0704
The boom can be slewed in a full circle without limitation (machines with slewing gear
transmission)
Cause Remedy
The slewing gear limit Repair slewing gear limit switch.

switch is defective or the
limit switch actuator is
b t
bent
Caution
The hydraulic and electric lines can be damaged if
the mast is slewed in the same direction a
number of times.
7.3 Boom Control This section describes the possible causes of defects affecting
the proportional boom control and how to remedy them.
Boom control has failed completely, no boom arm or support foot can be shifted
Cause Remedy
EMERGENCY OFF Unlock all EMERGENCY SHUT - DOWN push-buttons. If

function has been necessary, change from the radio control system to the cable
activated control.
The mode select Check fuses. Operate EMERGENCY SHUT - DOWN valve by
operating valve does not hand. If necessary, replace EMERGENCY SHUT - DOWN valve.
become live when the Emergency measure:
boom control is Execute individual boom functions by the manual lever with the
switched on EMERGENCY SHUT - DOWN valve pressed in.
7.4 Electrical System This section describes the possible causes of faults in the
electrical system and how to rectify them.
The radio transmitter has to be shaken to activate it
Cause Remedy
The batteries have Clean the contacts in the battery compartment thoroughly and
inadequate contacts in the bend carefully.
battery compartment
A820196_07_0704 7–9
Pump is switched on, but will not start
Cause Remedy
The specified minimum Increase engine speed.

engine speed for pumping
operations
ti off 900 rpm iis
not achieved
Pumping rate too low Increase pumping rate.
EMERGENCY Unlock all EMERGENCY SHUT - DOWN buttons.

SHUT - DOWN iis activated
ti t d
(EMERGENCY
SHUT - DOWN button
pressed)
10500200
The red indicator light for “fluid overheating” is lit
Cause Remedy
The hydraulic fluid has Allow the hydraulic fluid to cool and, if necessary, top up or
overheated replace the water in the water box.
The fan on the heat Check fan function and replace the fan motor if necessary.
exchanger is defective
Temperature sensor B1 is Replace temperature sensor. Hold temperature sensor connection

defective to ground to check.
The connection cable to Clean and fasten the connections on the temperature sensor.
the temperature sensor is
loose
7–10 A820196_07_0704
The red indicator light for “fluid overheating” is lit
Cause Remedy
The fan connection is Clean the terminals on the fan motor and fasten the connection
corroded cables properly.
Caution
Avoid contact with ground.
The vibrator fuse is blown
Cause Remedy
The vibrator is defective Replace defective vibrator. Fasten the grate cover on the hopper
or the hopper grate is and reduce the out - of - balance of the vibrator, if necessary.
loose
Vibrator cable is damaged Replace vibrator cable.
A820196_07_0704 7–11
The fan on the oil cooler no longer switches in automatically
Cause Remedy
Thermal contact switch B2 Check terminal (and ground contact). Replace thermal contact
switch (do not forget copper gasket). Switch on cooler motor by
defective (seat on the the manual switch.
connecting
ti flflange off th
the
cooler)
10501100
The radio remote control no longer operates perfectly, some functions are incorrect
Cause Remedy
Fuses in the receiver or Check fuses.

transmitter have blown To replace transmitter fuse, open transmitter casing with 4 mm
allen key.
To check the fuse in the receiver, unscrew casing lid, undo the
front printed circuit board (PCB) and flap down. The microfuses
are mounted on the rear PCB. The current ratings are marked
next to the fuses.
The engine speed reduces spontaneously
Cause Remedy
EMERGENCY Brief EMERGENCY SHUT - DOWN pulses from the radio control
SHUT - DOWN pulses system can be caused by radio interference. If necessary, move
from the radio control the transmitter site. In some circumstances on particular
system construction sites it will be necessary to work with the cable
remote control system. Change channel if the radio control system
has channel selection.
7–12 A820196_07_0704
The pump no longer switches over on every other stroke
Cause Remedy
Defective proximity switch, Refer to “Proximity Switch Junction Box” section on page 3 — 48
cable, or junction box. and “Proximity Switch Connector” section on page 3 — 50.
Replace defective component(s).
Note
On older models (with proximity switches in the
water box), a red LED on the side of the proximity
switches lights up when they are approached with
a metallic object (but not touched).
One coil on the stroke Replace stroke change valve (103a).

change
h valve
l (103
(103a)) iis
defective 106 Main connection block
181 Shut - off valve 120
119 181
121
184
103a
196
125
106 211
108
142 183
Connecting plug on the Check connector on the stroke change valve (103a).
stroke change valve
(103a) corroded
A820196_07_0704 7–13
7–14 A820196_07_0704
SAFETY BULLETIN
Setting Outriggers to Prevent Accidents
Oct. 26, 2005

American Concrete Pumping Association
606 Enterprise Drive
Lewis Center, OH 43035
614-431-5618
Appendix A
Appendix A
October 26, 2005 Safety Bulletin # 05001
Safety Bulletin
Setting outriggers
to prevent accidents
Background information When laying cribbing, spread the load. Use as

Tipping accidents have occurred as a result of: practical, especially on the side that will feel
the weight of the boom. Walk around the unit
• Inadequate cribbing
and center the outrigger pads and cribbing
• Misjudging the soil directly under each outrigger foot pad.
• Soil not compacted Before jacking the first outrigger, look under
• Setting up too close to excavations or the truck to be sure that no one has approached
backfilled areas the pad on the opposite side (Figure 1). When
• Hidden voids possible, use a spotter. As an outrigger is
• Wash outs jacked, the entire unit tips the opposite
direction. This tipping causes the outrigger on
• Natural or man-made voids the opposite side to become closer to the
Setting the outriggers of a concrete pump with ground. The weight and force of this movement
placing boom is one of the most critical jobs of could easily crush anything that comes
the concrete pump operator and should always between the outrigger and the ground. Be
be done in accordance with the manufacturer’s careful when jacking the outriggers!
recommended procedure. If not done properly,
it can lead to a serious accident.
Setting outriggers
When arriving at the jobsite, always check-in
with the contractor. Talk with the
superintendant or foreman regarding where to
set up safely. The contractor needs to supply a
safe set-up area where the soil is capable of
supporting the outriggers and there are no
voids, pipes, or other hidden dangers.
Always use the factory-supplied cribbing pads
or more, no matter what the surface, even if it is
on concrete. If jobsite conditions do not allow lookingunder.eps
full extension of all outriggers and you are Figure 1

required to shortrig, be sure that you Look under
understand all of the rules. If you do not
understand the rules, do not set up!
Appendix A
11/8/05
There are some additional do’s and
don’ts of outrigger stabilization:
Figure 2
Dos and don’ts of outrigger stabilization
• Do not set the outrigger on uneven soil (Figure When jacking, put the full weight of the truck on
2 A). If necessary, reposition the unit or level each outrigger, one at a time, and if the pad starts
the soil. to sink, retract the foot and supply more cribbing.
• Do not set the outrigger on a hill (Figure 2 B). Continue this process until the outrigger appears
The force of the machine weight must be stable and the pad shows no sign of sinking. Only
transmitted straight down. If you were to set up then are you ready to unfold the boom.
as shown in this example, the outrigger load If you are unable to get the outriggers to stabilize,
would be partially down and partially sideways, do not unfold the boom. Relocate the pump to a
putting undue strain on the outrigger leg. location that will support the weight of the
• Do not bridge a hole with outrigger cribbing outriggers.
(Figure 2 C). If there is no soil contact over the
hole, the pressure on the ends of the pad is
much greater. The soil could give way or the
cribbing could break.
• If you determine that you need five pieces of
cribbing to support the load but the foot only
touches three of them, the outrigger will sink
into the soil. To avoid this problem, lay dunnage
the opposite direction on top of the first layer
(Figure 2 D). The top layer of dunnage must
contact all pieces that are supporting it.
Appendix A
Page 2 of 10
Watch for warnings
ps
pads.e
twatch
boomou
Figure 3
Slowly slew the outrigger around the unit and watch for any outrigger sinking
As you unfold the boom, always test the stability Get as much cribbing as you need
of the unit. Slowly slew the extended boom over Safety and stability of the pump is everyone’s
each outrigger. If you see that an outrigger is concern. Most people will be happy to provide you
sinking into the soil, immediately slew the boom with whatever you need - especially if they know
back to the position it came from, and fold it up. their own safety is at stake. Wood dunnage is very
Adjust the amount of dunnage under the cribbing common and works well for well compacted, flat
pads until you have enough soil contact to hold the soil. If you are on soft soil or near the edge of an
unit without sinking. Repeat the procedure for excavation, it may be necessary to ask for a large,
each outrigger (Figure 3). Stability of the unit flat, steel plate to help distribute the weight.
must be ensured.
Retracting outriggers
While pumping, continue checking the outriggers
throughout the day to be sure they are not sinking. An outrigger may suddenly jump when weight is
removed, because the center of gravity on the
Other warning signs to watch for during your truck has shifted. Never stand behind the outrigger
initial set-up include: or between it and another fixed object when it is
• Very green grass in a circular shape being retracted (Figure 4). Clear the outrigger area
• Pipes sticking out of the ground of personnel before retracting outriggers.
• Signs of excavation
• Sprinkler heads
• Backfilled ditches
• Ditches with water in the bottom
outrigjump.eps
Figure 4
Don’t stand behind the outrigger
when it is being retracted
Appendix A
Page 3 of 10
Figure 5 sinking2.eps
Inadequate cribbing. Is the soil un-compacted

or soft?
sinking.eps
Figure 6
Warning clues
newbackfill.eps
The pictures in Figure 5 and Figure 6 show sink, the boom should be brought back to the
examples of signs of trouble when cribbing under travel position and adequate cribbing placed under
an outrigger is inadequate because of soil the outrigger.
conditions. Clue #1 in Figure 6 is a fresh pile of Figure 7, is an example of an accident with
dirt, indicating recent excavation. Clue #2 is the inadequate cribbing that occurred without
utility box which is another sign of recent warning. Virgin ground is capable of withstanding
excavation. Clue #3 is the outrigger (without only about 22 PSI of pressure. Because of that low
cribbing) beginning to sink into the soil. When the pressure capacity, the load must be spread over a
operator swings the boom over the outrigger, it large area.
will begin to sink. When the outrigger begins to
Had the operator provided a large area of cribbing
under the outrigger (like that in Figure 10), this
accident could have been avoided.
Figure 7
Punch through accident because of soil conditions
virginground.eps
Appendix A
Page 4 of 10
Do not partially extend outriggers
NO!
Outrigger
Inner Box
Outrigger
Reinforcements
Force
OK
Fulcrum
Outer Box
Reinforcements
nopartialextension.eps
1. Outrigger fully retracted.

No lever action.
Figure 8 Force absorbed by reinforcements.
Do not partially extend outriggers Force must be low, or unit will tip.
Fulcrum
CAUTION
Structural damage to outriggers is
Force
OK
possible. Do not jack outriggers unless Fulcrum
Force
they are either fully extended or fully
000467.eps
retracted.
Partial extension of telescoping outriggers is not 2. Outrigger fully extended.

acceptable at any time. Jacking the outriggers while Lever action present, but
force absorbed by reinforcements.
they are in any position other than fully extended or
force&leverOUTRIG.eps
fully retracted could cause structural damage to the
outrigger outer box and/or the inner box (Figure 8).
Fulcrum Fulcrum
The three illustrations shown in Figure 9 explain the
situation with the outrigger in all positions.
Remember that the boom must never be extended over
a retracted outrigger. Force
Force
NO!
Figure 9 3. Outrigger partially extended.
Partial extension can cause Lever action present, but force transmitted
damage to the outrigger to areas with no reinforcements. Could cause damage.
Appendix A
Page 5 of 10
Figure 10
Outrigger load spread properly to avoid the
possibility of accidental punch-through
spreadload.eps
Figure 10 shows an effective way to spread the Excavations and cliffs

load of the outrigger foot and bring the pressure If set-up will be done near an excavation, the one-
imposed on the ground to a minimum. to-one rule must be applied (Figure 11). The
outrigger force emits pressure as a 45˚ cone below
4’ x 8’ sheet of steel = 4608 square inches the surface, so it is very important to be aware of
Outrigger force = 32,600 washouts at the base of an embankment as shown
by the “X” in Figure 12. Engineered support walls
32,600 ÷ 4608 = 7.07 PSI can be treated differently than excavations, and the
operator may follow the advice of the contractor or
engineer on the job if he believes the advice to be
sound.
NOTE!
Measurement for the one-to-one rule should
be made from the edge of the outrigger pad
nearest the excavation, and the distance
from the edge should be increased if soil
conditions are bad or if the manufacturer’s
recommendation is more restrictive.
1to1rule.eps
THE ONE TO ONE RULE:

FOR EVERY 1 FOOT OF VERTICAL DROP,
STAY BACK FROM THE BASE EDGE 1 FOOT.
(DISTANCE "B" MUST BE EQUAL TO
DISTANCE
B OR GREATER THAN DISTANCE "A")
Figure 11
base edge DISTANCE
One-to-one rule A
Figure 12
Watch for this 45 Degrees
(Soil washed out at the “X”) X
Appendix A
Page 6 of 10
Hidden voids are hidden hazards
hidden voids.eps
Figure 13
Examples of underground hazards
Unless an operator has x-ray vision, there is no
way he can tell if he is setting up over a hidden
void (Figure 13). Some voids, like septic systems,
may have a pipe protruding from the ground.
Sprinkler heads would give some indication that
there might be buried hazards. But some voids,
like a buried box, leave no clues for even the
safest-minded operator. His only chance is
spreading the load.
Figure 14 shows an example of a punch-through
that occurred without warning because of an
underground void. The pour had progressed for
some time with no warning of the outrigger
sinking when it suddenly punched through and
brought the boom crashing down.
punchthrough.eps
Figure 14
Hidden voids cause accidents
Appendix A
Page 7 of 10
Inadequate cribbing load bearing capacity of 58 PSI. If an outrigger
The formula for determining the load imposed on was placed on the manufacturer’s supplied
the soil is to divide the total outrigger force cribbing pad, which has 576 square inches of
(pounds) by area of soil contact (square inches). surface, it could technically support the unit.
Soil pressure = total outrigger force ÷ area of soil 32,600 ÷ 576 = 56.59 PSI
contact It is easy to misjudge the soil material or
The following chart shows a few of the different compaction, and the information is often not
soil types and their approximate load-bearing available. The best case scenario would be to
capacities: spread out the load considerably more than the 576
square inches by placing a larger base under the
Soil Type and Approx. Load-bearing Capacity supplied pad. For example, ten 36” long 4x4’s
Virgin ground................................ 22 PSI (1260 square inches) or a 4 foot x 8 foot (4608
Asphalt.......................................... 29 PSI square inches) sheet of strong material (like steel)
Compressed, crushed stone........... 36 PSI would lower the outrigger pressure dramatically,
Clay/silt soil, firm.......................... 43 PSI reducing the chance of an outrigger sinking or
Mixed granular soil....................... 51 PSI dropping.
Firm, compacted gravel................. 58 PSI Operators are not expected to make calculations
Brittle, weathered rock..................145 PSI such the one shown above while on a jobsite. This
information is given only to show that the ground
Misjudging the soil has many different load bearing capacities, and
Operators rarely have access to the compaction boom trucks all impose a different force on the
data of a jobsite, and will generally have to make soil. The bottom line is this, the greater the force
judgment calls. Because of this, they should make imposed on the soil, the larger the dunnage area
the cribbing base as large as is practical. must be.
An example:
The decal on a pump outrigger shows a maximum
force of 32,600 pounds (Figure 15). The soil is
firm, compacted gravel, which has an approximate
32,600 LBS
Figure 15
Pump outrigger decal example
Appendix A
Page 8 of 10
Summary • Have a place prepared for the pump before it
arrives on the job.
Prevention
• Inform the operator of backfilled areas, soft or
Tip-over accidents can be avoided if people take
muddy areas, or underground obstructions.
precautions when the unit is set up. Both operators
and contractors must be aware of the potential • Have cribbing nearby the set-up area prior to
danger that exists when a large boom is unfolded the pump’s arrival (including steel sheets if the
and extended over outriggers. If the contractor soil is known to be bad).
remembers to offer additional cribbing and if the • Monitor the set-up. Don’t let the operator cut
operator remembers to ask for it when it isn’t corners or take chances.
offered, the problem can be minimized even
Dispatcher
before the boom is extended.
The dispatcher can help by communicating with
Cribbing: more or less? the contractor when he calls to order the pump,
• More is better and:
• The stronger the material the better • Send the size pump that is needed, if available.
• Pay close attention to the type of soil where • If availability causes you to send a unit that is
you’re setting up the unit. too big or too small, warn of possible
complications.
Training
• Ask about soil conditions or underground
Every person in the chain of a pumping job has a
obstructions.
responsibility to help protect the hose person and
other nearby personnel. Education is the key, Operator
followed closely by diligent watchfulness and The operator is ultimately in charge and must
personal protective equipment. Educational make good decisions regarding set-up including:
materials are available from the ACPA, and
everyone involved in the concrete pumping • Use as much cribbing as practical; too much is
process should be trained, including: better than too little.
• Job superintendents • Watch for all warning signs prior to set-up.
• Labor foremen • Watch for sinking outriggers while unfolding
the boom, and continue to recheck them
• Laborers throughout the day.
• Pump operators • Keep people out from under the boom
Responsibilities whenever practical.
Contractors
• One of the things a contractor can do to help is This document is intended to supplement, but not
to order the right size boom: supersede the manufacturer’s applicable instruc-
tions.
• If the boom is too small, for example, he
may have to set up too close to an
excavation to reach the pour. - By Danny Mace and Robert Edwards,
• If the boom is too large, it will require Edited by the ACPA.
much more cribbing than a smaller unit.
Appendix A
Page 9 of 10
Appendix A
Page 10 of 10
Appendix B
Ergonic Boom Control (EBC)

(If Equipped)
Operating Instructions
BSF 43 - 5 RZ
Table of Contents
Appendix B
B EBC Operating Instructions B1 — 2
1 Guide to the Operating Instructions . B1 — 2

1.1 Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1 — 3
1.2 Icons and Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1 — 5
2 Safety Regulations . . . . . . . . . . . . . . . . . 2 — 1
2.1 Basic principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 2
2.2 Designated use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 — 2
2.3 Use contrary to the designated use . . . . . . . . . . . . . . . . . . . . . . . . . . 2—2

2.3.1 High--voltage lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2—2
2.3.2 Defective EBC components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2—3
2.3.3 Exclusion of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2—3
3 General Technical Description . . . . . . . 3 — 1

3.1 What is EBC? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 2
3.1.1 How does EBC work? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 2
3.1.2 EBC control symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 2
3.1.3 Ergonic Boom Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 4
EBC operating elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 5
Selector switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 7
Teach acknowledgement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 8
Boom damping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 8
Joystick in general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 8
Left--hand joystick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 9
Right--hand joystick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 10
3.1.4 EBC control cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 10
EMERGENCY SHUT--DOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 11
A820196_Appendix B--TOC_0704 I
Table of Contents
4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.1 Setting Up with EBC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 — 2
4.2 Unfolding and Folding the Placing Boom . . . . . . . . . . . . . . . . . . . . . 4 — 4

4.2.1 Unfolding the placing boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Arm 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Slewing the boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Starting the unfolding program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Example showing individual stages in the semi−automatic unfolding
of the M43/47−5 RZ placing boom as far as the end position . . . . . 47
4.2.2 Folding the placing boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Starting the folding program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Example showing individual stages in the semi−automatic folding
of the M43/47−5 RZ placing boom . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
Lowering the arm assembly onto the cradle . . . . . . . . . . . . . . . . . . . 412
4.3 Preferred Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 — 13

4.3.1 Preferred position for arm 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
Example of preferred position for arm1 . . . . . . . . . . . . . . . . . . . . . . . 414
Starting position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414
Storing a preferred position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
Deleting a preferred position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
4.3.2 Preferred position for arm 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
Storing a preferred position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
Deleting a preferred position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
4.4 Selecting the Preferred Folding Configuration . . . . . . . . . . . . . . . 4 — 20

Arm movements in the arc configuration" . . . . . . . . . . . . . . . . . . . . . 420
Arm movements in the Z configuration" . . . . . . . . . . . . . . . . . . . . . . 420
4.4.1 Selecting the Z configuration" as preferred
folding configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
Storing the preferred folding configuration . . . . . . . . . . . . . . . . . . . . . 422
4.4.2 Selecting the arc configuration" as preferred
folding configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
Storing the preferred folding configuration . . . . . . . . . . . . . . . . . . . . . 423
4.5 Moving the End Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 — 24
4.6 Programming the Upper and Lower Limits . . . . . . . . . . . . . . . . . . 4 — 25

II A820196_Appendix B -TOC_0704
Table of Contents
4.6.1 Programming the upper limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428

4.6.2 Programming the lower limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429
4.6.3 Moving the end hose within the limits . . . . . . . . . . . . . . . . . . . . . . . . . 430
4.6.4 Deleting limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
4.7 Boom Damping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 — 33

Activating boom damping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433
A820196_Appendix B -TOC_0704 III

Table of Contents
IV A820196_Appendix B -TOC_0704
Appendix B EBC Operating Instructions
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 questions:
Putzmeister America
Customer Support Group
1733 90th Street
Sturtevant, WI 53177 USA
Telephone (800) 890 - 0269

Telefax Wisconsin Parts (262) 884 - 7259
Telefax California Parts (562) 229 - 1713
www.putzmeister.com
or your local servicing dealer or branch:
Address:
Telephone:
Telefax:
e - mail:
A820196_Appendix B - 1_0704 B1 — 1
1.1 Foreword These Operating Instructions only describe the Ergonic functions.
is a registered brand name for all Putzmeister

components which control concrete pumps and placing booms. These
Operating Instructions are designed to familiarize the user with the
Ergonic functions and to assist him in using these functions properly in
various operations.
These Operating Instructions are a supplement to the machine Operating

Instructions. They are only valid in conjunction with the machine
Operating Instructions.
The Operating Instructions contain important information on how to

operate the machine safely, properly and economically. Observing these
instructions helps to avoid danger, to reduce repair costs and downtimes,
and to increase the reliability and service life of the machine.
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, fault rectification in the course of work,
removal of production waste, maintenance and disposal of fuels and
consumables;
-- service (maintenance, inspection, repair), and/or
-- transport.
The generally--recognized rules of technology for safe and proper

working must be observed in addition to the Operating Instructions and
mandatory rules and regulations for accident prevention in the country
and place of use of the machine.
B1 — 2 A820196_Appendix B--1_0704
Should you have any questions following your study of the Operating
Instructions, the Putzmeister Customer Support Group, or Dealer serving
you, 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.
Modifications are made from time to time in the interests of constant

improvement and it may be the case 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 Instructions

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 authorization
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.
© Copyright by Putzmeister PMA 2007
A820196_Appendix B - 1_0704 B1 — 3
1.2 Icons and Symbols The following icons and symbols are used in the Operating Instructions:
" Action symbol

Text following this symbol describes actions which you are required to
work through, generally in the sequence shown from top to bottom.
å Text following this symbol describes the result or effect of an action.

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

This icon identifies the special tools necessary to carry out the work. Nor-
mal tools, ie commercially - available tools or tools carried in the truck, are
not specially listed.
Note
Particular information regarding economic use of the machine is
introduced with the icon illustrated, the word Note printed in bold, and a
line. 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 with the icon illustrated, the word Caution printed in bold,
and a line. The associated text is printed in italics and ends with another
line.
Danger
personal injury or significant damage are introduced with the icon
illusrated, the word Danger printed in bold, and a line. The associated
text is printed in italics and ends with another line.
B1 — 4 A820196_Appendix B - 1_0704
2 Safety Regulations
This chapter summarizes the most important safety regulations.

This chapter is, therefore, particularly suitable as an initial basic
instruction for new operators. Naturally, the various rules are also
repeated once more at the appropriate points in the Operating
Instructions.
Note
For further reference, please refer to the ACPA (American Concrete
Pumping Association) Safety Manual" included with this manual.
A820196_Appendix_B−2_0704 B21
Safety Regulations
2.1 Basic principle The safety regulations in the Operating Instructions for this machine
apply whenever the machine is operated.
The machine may only be operated with the EBC control if this is
functioning correctly.
2.2 Designated use The EBC control is a semi - automatic operating device for the placing
boom. It makes operation of the machine easier and helps the machine
operator to operate the machine more safely.
Even when the EBC control is used as designated, incorrect operation by

the machine operator, an error by the site personnel, a fault or the
breakdown of the control system can result in hazardous situations. The
machine operator is responsible for operating the machine with the EBC
control. He must therefore always keep an eye on the placing boom and
its field of use to recognise potential dangers in good time.
The machine operator must push and hold the corresponding

operating/control element to execute EBC functions.
2.3 Use contrary to the The EBC control must not be used to bypass valid safety regulations.
designated use
2.3.1 High - voltage lines The EBC control can be used to program an upper limit for the placing
boom. The use of this function for placing the boom under high - voltage
lines is nevertheless prohibited. If the EBC control malfunctions or breaks
down, the programmed upper limit deceives the operator by appearing to
offer safety which is actually non - existent. Furthermore, in wet weather,
flash overs may occur when the boom approaches high - voltage lines.
B22 A820196_Appendix_B−2_0704
Safety Regulations
2.3.2 Defective EBC The EBC control must no longer be used if an EBC component is
components defective. If even one angle sensor or pressure sensor malfunctions, the
EBC control will no longer function correctly. The machine must continue
to be operated without EBC functions if an EBC component malfunctions.
You must have the fault rectified by qualified personnel before using the
EBC control again.
If components are replaced in conjunction with a safety circuit

(e.g. redundant load moment monitoring), qualified personnel must carry
out an extended function check.
2.3.3 Exclusion of liability We state here expressly that Putzmeister accepts no liability for damage
arising from incorrect or negligent operation, servicing or maintenance or
as a result of use contrary to the designated use. This statement is
equally valid for modifications to, additions to and customization of the
EBC control which may compromise safety. The warranty will no longer
be valid in such cases.
A820196_Appendix_B−2_0704 B23
Safety Regulations
B24 A820196_Appendix_B−2_0704
3 General Technical Description
This chapter describes the Ergonic operating elements and explains how
they function. Please note that any options fitted will also be described.
The machine card will tell you whether the option described is fitted to
your machine.
A820196_Appendix_B - 3_0704 B3 — 1
3.1 What is EBC? EBC (Ergonic Boom Control) is a computer - aided control system used to
control the placing boom. Among other functions, EBC allows you to
move the placing boom using just one joystick. The EBC functions
include:
- Semi - automatic raising and lowering of the placing boom
- Self - collision protection
- Defining upper and lower limits for the placing boom (to prevent
collisions in the 3D operating range)
- Moving the end hose linearly
- Damping the bounce of the placing boom
- Defining preferred positions (e. g. last arm always horizontal)
3.1.1 How does EBC work? EBC constantly calculates the position of the placing boom and the end
hose in the 3D operating range. To this end, the EBC computer receives
signals from the spatial sensors on each arm and the pressure sensors
on the hydraulic cylinders. Together with the control commands received
from the radio remote control, EBC calculates the control signals which
are transmitted to the boom control block.
3.1.2 EBC control symbols This section gives you a summary of the symbols used for control
actions.
Note
The EBC control symbols for a placing boom with 4 arms are shown
below. The symbols for a 3 - arm or 5 - arm placing boom are similar.
Where symbols have more than one meaning, the EBC function is shown
in red.
B3 — 2 A820196_Appendix_B - 3_0704
1 2 3 4
5 6 7 8
A820196_Appendix_B−3_0704 1
No. 0 Designation
1 End hose up
2 End hose down
3 End hose forwards
4 End hose back
5 End hose to the left
6 End hose to the right
7 Unfolding the placing boom
8 Folding the placing boom
A820196_Appendix_B - 3_0704 B3 — 3
1 2 3 4
5 6 7 8
A820196_Appendix_B−3_0704 2
No. 0 Designation
1 Normal operation, controlling arms individually
2 Individual axle operation, controlling arms individually
3 EBC operation, moving the end hose
4 Semi - automatic operation
5 Boom damping
6 Programming operation
7 Storing
8 Clearing the memory
3.1.3 Ergonic Boom Control Ergonic Boom Control (EBC = computer - aided control system for
controlling the placing boom) helps you to move the placing boom using
just one joystick. The operating elements for the EBC functions on the
proportional radio remote control transmitter are described below.
Note
The transmitter for a placing boom with 4 arms is shown below.
The functions for a 3 - or 5 - arm placing boom are the same.
B3 — 4 A820196_Appendix_B - 3_0704
EBC operating elements

2 3 4
ÁÁÁ
ÁÁÁ
ÁÁ
1
ÁÁ ÁÁ
ÁÁ ÁÁ
ÁÁ
ÁÁ
A820196_Appendix_B−3_0704 3
Operating/ Selector
No. 0 Meaning/function
control element switch
1 Individual axle operation:
Control boom arms individually
2 Move end hose
1 Selector switch
3 Semi - automatic operation
4 Programming operation
5 corresponds to switch position 1
→
A820196_Appendix_B - 3_0704 B3 — 5
2 3 4
ÁÁÁ
ÁÁÁ
ÁÁ
1
ÁÁ ÁÁ
ÁÁÁ ÁÁ
ÁÁÁ
ÁÁÁ
A820196_Appendix_B−3_0704 4
Continued
Operating/ Selector
No. Meaning/function
control element switch
1 Control boom arms individually
Turning: Preferred position for arm 1
2 Forwards - back: Preferred position for last arm
2 Left - hand jjoystick
y Left - right: Activate boom damping
Forwards - back: Unfold and fold placing boom
3
Left - right: Activate boom damping
4, 5 Control boom arms individually
3 Toggle switch Storing and deleting
1 Control boom arms individually
Turning: End hose up - down
4 Right
g - hand jjoystick
y 2 Left - right: Slew placing boom
Forwards - back: End hose forwards - back
3, 4, 5 Control boom arms individually
B3 — 6 A820196_Appendix_B - 3_0704
Special features of the radio remote control
Caution
The EBC functions are always activated. Never take your eye off the
machine during pump and boom operation. In the event of a fault, the
placing boom could make unintended movements which could injure
persons or cause damage.
STOP button Putzmeister radio remote controls include a STOP button which has the
same function as the EMERGENCY SHUT - DOWN buttons on the
machine. This is a requirement of European standard EN 60204 - 1.
Restarting the pump You may only start the pump up again as described below if you have
after STOP pressed the STOP button:
- Unlock the STOP button by turning it,
- move the “Boom functions - 0 - Support leg control” toggle switch to
the zero position,
- switch the remote control unit off and back on again,
toggle switch,
- switch the pump off and then on again using the “Forward pumping - 0
- Reverse pumping” toggle switch.
Selector switch You can select different operating modes using the selector switch.
- Switch position 1 allows you to control the machine in the
“Computer - aided normal” operating mode. You can control each of the
boom arms individually.
- Switch position 2 allows you to control the machine in the “Move end
hose” operating mode. The end hose is controlled with just one
joystick and all the arm movements are computer - aided.
- Switch position 3 allows you to control the machine in the
“Semi - automatic” operating mode. The placing boom is folded and
unfolded with just one joystick and all the arm movements
are computer - aided.
- Switch position 4 allows you to program an upper and lower limit for
the “Move end hose” operating mode. You can control each of the
boom arms individually in this switch position
- Switch position 5 corresponds to switch position 1.
A820196_Appendix_B - 3_0704 B3 — 7
Teach acknowledge- You can store an upper and lower limit for the boom movements
ment or a preferred position for the first and last arm using the “Teach
acknowledgement“ toggle switch.
Note
All the stored values are automatically deleted if you switch off the truck
engine at the ignition or disengage the power take - off.
Boom damping The boom movements are damped to prevent the placing boom from
bouncing during pumping. Boom damping is always active when an EBC
function is operated, i.e. as long as you are operating a joystick. If you do
not move the placing boom during pumping, boom damping is only active
while you hold the left “Activate boom damping” joystick in a position.
Note
If you do not move the placing boom, boom damping may only be
activated if the pumping rate is set to at least 20 %.
Joystick in general The joysticks are used to proportionally control the placing boom, i.e. the
boom arm movement speeds are increased or reduced depending on
how far you move the joystick.
You must not release the joystick suddenly, but move it back to the
centre position under control to prevent the placing boom from stopping
abruptly and then bouncing.
B3 — 8 A820196_Appendix_B - 3_0704
Left - hand joystick The following functions are controlled by the left - hand joystick in
accordance with the switch position of the selector switch:
- Selector switch in switch position 1:
Computer - aided normal operation.
Preferred positions for first and last arm.
The preferred position means that you can change the position of the
first and last arms without changing the position of the end hose. The
positions of the other arms are adjusted under computer control.
The boom damping is activated for as long as you keep the joystick
pushed to the left or right.
- Selector switch in switch position 3: Semi - automatic operation.
The placing boom will continue to unfold or fold while you keep
the joystick pushed forwards or backwards. Arm movements are
executed under computer control. The placing boom stops as soon as
you release the joystick.
The boom damping is activated for as long as you keep the joystick
pushed to the left or right.
- Selector switch in switch position 4: Programming operation
You can move individual arms of the placing boom.
A820196_Appendix_B - 3_0704 B3 — 9
Right - hand joystick The following functions are controlled by the right - hand joystick in
accordance with the switch position of the selector switch:
- Selector switch in switch position 2: Move end hose
You can move the end hose backwards and forwards or to the left or
right at a constant height by moving the joystick. By turning the joystick
you move the end hose up and down without changing its lateral
position. The positions of all the arms are adjusted under computer
control. The placing boom stops as soon as you release the joystick.
- Selector switch in switch position 3: Semi - automatic operation.
Raising and lowering arm 1, slewing the placing boom.
- Selector switch in switch position 4: Programming operation
You can move individual arms of the placing boom.
3.1.4 EBC control cabinet The EBC control cabinet contains the EBC computer. The EBC control
cabinet is only functional if the machine is operating in EBC mode.
B3 — 10 A820196_Appendix_B - 3_0704
1 2
A820196_Appendix_B-3_0704 5
Operating/ Belongs
1 Green indicator lamp Ready for service
2 Red indicator lamp EMERGENCY SHUT - DOWN activated
Special features of the EBC control cabinet
EMERGENCY SHUT - When the machine is set up with EBC, the “Boom functions - 0 -
DOWN Support leg control” toggle switch must not be in the “Support leg control”
switch position on the radio remote control, otherwise the EMERGENCY
SHUT - DOWN cannot be cancelled.
Note
If the EMERGENCY SHUT - DOWN indicator lamp on the EBC control
cabinet does not go out, you must:
– Switch off the radio remote control transmitter,
– Move the “Boom functions - 0 - Support leg control” toggle switch to
the zero position,
– Switch the transmitter back on,
– Cancel the EMERGENCY SHUT - DOWN using the “Horn” toggle
switch.
A820196_Appendix_B - 3_0704 B3 — 11
B3 — 12 A820196_Appendix_B - 3_0704
4 Operation
In this chapter you will find information concerning operation of the

machine with Ergonic. The procedures described in the machine
Operating Instructions are also valid in addition to the operations
described here.
A820196_Appendix_B −4_0704 B41

Operation
4.1 Setting Up with EBC The procedures listed below must be observed when setting up the
machine with EBC.
2
10
3 8
7 9
4
A820196_Appendix_B-4_0704 31
No 0 Designation
1 Central control cabinet
2 EBC control cabinet
3 Radio remote control receiver
4 Radio remote control transmitter
5 Cable remote control transmitter
6 Connector to boom control block
7 Female connector from the EBC control cabinet
(EBC operation)
8 Female connector from the central control cabinet
(operation without EBC)
9 Boom control block
Female connector to the central control cabinet for input
10
signals from the radio or cable remote control
" First connect the control components as shown above.
B42 A820196_Appendix_B −4_0704

Operation
Note
The central control cabinet and the EBC control cabinet are supplied with
power as soon as you switch on the power take - off. The EMERGENCY
SHUT - DOWN is activated at the same time. The red “EMERGENCY
SHUT - DOWN” indicator lamp lights up on both control cabinets. You
must press the horn toggle switch once to deactivate the EMERGENCY
SHUT - DOWN.
The EMERGENCY SHUT - DOWN on the EBC control cabinet can only
be deactivated if the locally latched “Boom function - support leg control”
toggle switch is at the “0” position before you switch on the radio remote
control.
Á
Á Á
Á
A820196_Appendix_B-4_0704 1
" Switch the locally latched “Boom function - support leg control”
toggle switch to switch position “0”.
" Engage the power take - off.
" Switch the radio remote control on.
" Press the horn toggle switch.
A820196_Appendix_B −4_0704 B43

Operation
4.2 Unfolding and Folding You can unfold and fold the placing boom semi - automatically using just
the Placing Boom one joystick. Arm movements are executed under computer control.
Caution
The program for unfolding and folding the placing boom is a
semi - automatic program. Only arms 2 to 5 are controlled. You have to
control arm 1 and the slewing gear yourself.
The program contains an integrated anti - collision function for the arms,
but does not include an anti - collision function to prevent the arms from
colliding with the truck, the truck superstructure or obstacles on the
construction site.
You should further note that the end hose (depending on the machine’s
equipment) is positioned loosely in the end hose brackets and hangs
down freely when the boom is being folded in and out.
Therefore you must always keep an eye on the placing boom while it is
being unfolded or folded semi - automatically.
ÁÁ
Á
Á Á
A820196_Appendix_B −4_0704 2
" Shift the selector switch to switch position 3.
B44 A820196_Appendix_B −4_0704

Operation
4.2.1 Unfolding the Follow the procedure described below to unfold the placing boom
placing boom semi - automatically.
Note
The semi - automatic unfolding program will not start until you have raised
arm 1 to an angle of at least 65_. Once the program is running, you can
change the position of arm 1 to any position.
Arm 1
65°
A820196_Appendix_B −4_0704 3
Raising arm 1
" Raise arm 1 through at least 65°.
A820196_Appendix_B −4_0704 B45

Operation
Slewing the boom
A820196_Appendix_B −4_0704 4
Slewing the placing boom
" Slew the placing boom in the required direction.
Starting the unfolding

program
ÁÁ
ÁÁ
ÁÁÁÁ
A820196_Appendix_B −4_0704 5
" Unfold the placing boom semi - automatically by pushing the left -
hand joystick forwards.
B46 A820196_Appendix_B −4_0704

Operation
å The placing boom will continue to unfold for as long as you

keep pushing the joystick.
Note
Arms 2 to 5 are unfolded at the same time. The unfolding speed is
proportional to the deflection of the joystick. In addition, arms 2 to 5 are
unfolded so that all the arms reach their end position simultaneously.
You can stop the semi - automatic unfolding program at any position by
returning the joystick to the centre position.
abruptly and hence bouncing.
If you have stopped the semi - automatic unfolding program, you can, for
example, switch the selector switch to “Normal operation”, move any arm
individually, then switch the selector switch back to “Semi - automatic
operation”, and continue the semi - automatic unfolding program from this
position.
Note
The M 43/47 - 5 RZ placing boom end position means:
– Arm 1 remains in the position to which you move it
– Arm 2 points upwards at an angle
– Arm 3 points vertically downwards
– Arm 4 points upwards at an angle
– Arm 5 and the end hose point vertically downwards
A820196_Appendix_B −4_0704 B47

Operation
Example showing individual stages in the semi - automatic unfolding

of the M 43/47 - 5 RZ placing boom as far as the end position
A820196_Appendix_B −4_0704 6
B48 A820196_Appendix_B −4_0704

Operation
4.2.2 Folding the Follow the procedure described below to fold the placing boom
placing boom semi - automatically. You can start the semi - automatic folding program for
the placing boom from any position of the arm assembly.
Starting the folding

program
ÁÁ
ÁÁ
ÁÁÁÁ
ÁÁ A820196_Appendix_B −4_0704 7
" Fold the placing boom semi - automatically by pulling the left - hand
joystick backwards.
A820196_Appendix_B −4_0704 B49

Operation
Note
Arms 2 to 5 are folded at the same time. The folding speed is
proportional to the deflection of the joystick. In addition, arms 2 to 5 are
folded so that all the arms reach their end position.
You can stop the semi - automatic folding program at any position by
returning the joystick to the centre position.
abruptly and hence bouncing.
If you have started the semi - automatic folding program from an

inappropriate boom position, the placing boom may suddenly stop
because an arm would otherwise collide with another arm. If this
happens, switch the selector switch to “Normal operation” and move the
arm individually. Then switch the selector switch back to
“Semi - automatic operation” and continue the semi - automatic folding
program.
B410 A820196_Appendix_B −4_0704

Operation
Example showing individual stages in the semi - automatic folding

of the M 43/47 - 5 RZ placing boom
A820196_Appendix_B −4_0704 8
A820196_Appendix_B −4_0704 B411

Operation
Lowering the arm

assembly onto
the cradle
2.
1.
A820196_Appendix_B −4_0704 9
Slewing and lowering the arm assembly
" Slew the arm assembly until it is in the storage position and then
lower it.
B412 A820196_Appendix_B −4_0704

Operation
4.3 Preferred Positions You can set and store a preferred position for arms 1 and 5 in the “Move
end hose” operating mode. When you have stored a preferred position
for an arm, all subsequent boom movements on that arm will stop at the
position you have stored.
Note
When a preferred position is stored, the position of the last arm which
was moved is always saved.
If you have stored a preferred position and then move the arm for which
the position was stored, the new end position of the arm is automatically
stored as the preferred position. This new preferred position is
maintained so long as the machine is in the “Move end hose” operating
mode.
If you have stored a preferred position and then change the operating
mode, the last arm position will still be the preferred position when you
reselect the “Move end hose” operating mode.
When a preferred position is deleted, all the preferred positions are

always deleted at the same time. The preferred positions are also
deleted if you switch off the truck engine ignition or the power take - off.
A820196_Appendix_B −4_0704 B413

Operation
4.3.1 Preferred position If you store a preferred position for arm 1, it will not move with any
for arm 1 subsequent arm movements.
Example of preferred
position for arm 1
A820196_Appendix_B −4_0704 10
Starting position
A820196_Appendix_B −4_0704 11
1 Fixed point
B414 A820196_Appendix_B −4_0704

Operation
Á
Á
Á Á
A820196_Appendix_B −4_0704 12
" Move the EBC selector switch on the radio remote control to switch
position 2.
ÁÁ
ÁÁ
Á Á
Á
A820196_Appendix_B −4_0704 13
1 Fixed point
" Turn the left - hand joystick to the right.

å Arm1 moves upwards and the boom tip remains unchanged in
its position. The positions of the other arms are adjusted under
computer control.
A820196_Appendix_B −4_0704 B415

Operation
Storing a preferred
position
ÁÁ
ÁÁ
Á Á
A820196_Appendix_B −4_0704 14
" Push the “Storing and deleting” toggle switch up to store the pre-
ferred position.
Deleting a preferred
position
ÁÁ
ÁÁ
Á
Á Á
A820196_Appendix_B −4_0704 15
" Push the “Storing and deleting” toggle switch down to delete the
preferred position.
Note
This always deletes the preferred positions on both arms.
B416 A820196_Appendix_B −4_0704

Operation
4.3.2 Preferred position If arm 5 is horizontal, the concrete flow rate will be slower. This reduces
for arm 5 wear on the delivery line and the end hose.
Starting position
A820196_Appendix_B −4_0704 16
1 Fixed point
Á
Á
Á Á
Á
A820196_Appendix_B −4_0704 17
position 2.
A820196_Appendix_B −4_0704 B417

Operation
ÁÁ 1
ÁÁ
Á Á
Á
A820196_Appendix_B −4_0704 18
1 Fixed point
" Pull the left - hand joystick backwards.

å The hinge on the last arm moves downwards, the arm is
placed horizontally and the boom tip remains unchanged in its
position. The positions of the other arms are adjusted under com−
puter control.
B418 A820196_Appendix_B −4_0704

Operation
Storing a preferred
position
Á
Á
Á Á
A820196_Appendix_B −4_0704 19
ferred position.
Deleting a preferred
position
Á
Á
Á
Á Á
A820196_Appendix_B −4_0704 20
" Push the “Storing and deleting” toggle switch down to delete the
preferred position.
Note
This always deletes the preferred positions on both arms.
A820196_Appendix_B −4_0704 B419

Operation
4.4 Selecting the Preferred You can select and store a preferred folding configuration for the
Folding Configuration arm assembly in the “Normal operation” operating mode. You then
control the arm assembly in the selected type of configuration for all
boom movements in the “Move end hose” operating mode.
Note
The factory default setting for the preferred folding configuration is
the arc configuration. This default setting is stored every time the
machine is put into operation. You may have the default setting modified
at any time by a Putzmeister service technician.
Arm movements in the “arc configuration”
A820196_Appendix_B-4_0704 21
Arm movements in the “Z configuration”
A820196_Appendix_B-4_0704 22
B420 A820196_Appendix_B −4_0704

Operation
4.4.1 Selecting the “Z configuration” as preferred folding configuration
Á
Á
Á Á
Á
A820196_Appendix_B-4_0704 23
position 1 (Normal operation).
< 180_
A820196_Appendix_B-4_0704 24
" Unfold the arm assembly until the unfolded angle between arm 2
and arm 3 is less than 180_.
A820196_Appendix_B −4_0704 B421

Operation
Storing the preferred

folding configuration
ÁÁ
ÁÁ
Á Á
A820196_Appendix_B-4_0704 25
ferred folding configuration.
Note
The preferred folding configuration that was stored at the works is
resumed if you switch off the truck engine ignition or disengage the
power take - off.
4.4.2 Selecting the “arc configuration” as preferred folding configuration
ÁÁ
ÁÁÁ
Á Á
A820196_Appendix_B-4_0704 26
position 1 (Normal operation).
B422 A820196_Appendix_B −4_0704

Operation
> 180_
A820196_Appendix_B-4_0704 27
" Unfold the arm assembly until the unfolded angle between arm 2
and arm 3 is greater than 180_.
Storing the preferred

folding configuration
Á
Á Á
Á Á
A820196_Appendix_B-4_0704 28
ferred folding configuration.
Note
The preferred folding configuration that was stored at the works is
resumed if you switch off the truck engine ignition or disengage the
power take - off.
A820196_Appendix_B −4_0704 B423

Operation
4.5 Moving the End Hose The end hose movements are controlled by just one joystick.
The positions of all arms are adjusted under computer control.
ÁÁ
ÁÁÁÁ
Á
A820196_Appendix_B −4_0704 29
position 2.
Á
Á
ÁÁÁÁ
ÁÁ
A820196_Appendix_B −4_0704 30
" Move the end hose using the right - hand joystick.
B424 A820196_Appendix_B −4_0704

Operation
4.6 Programming the Set an upper and lower limit for the boom to prevent the arm assembly
Upper and Lower from touching the ceiling or floor when concreting in low buildings, for
Limits example. Computer - aided control then helps you to keep all the
subsequent arm movements within this corridor.
Note
Please note the following points:
– Do not set your limits too close to the actual, physical limits. If you
change the operating mode and accidentally operate the wrong boom
function, you will have no reaction time to counteract your actions.
– The distance between the upper and lower limits must be at least 14 m
(M 43 - 5 RZ) and 15 m (M 47 - 5 RZ), otherwise the arm assembly will
stop very prematurely.
– The height of the slewing gear centre is the zero line. The limit above
the zero line is automatically the upper limit and the limit below the
zero line is automatically the lower limit. It is not possible to set two
limits above or below the zero line.
– The boom tip must be at the uppermost or lowermost point of the
boom when you are programming. For example, if the B - hinge (hinge
between arms 1 and 2) is above the boom tip when you are
programming the upper limit, the program reports a collision and will
not start.
High voltage
Placing the boom under high - voltage lines is prohibited even if the upper
limit has been programmed.
If the EBC control malfunctions or breaks down, the programmed upper

limit deceives the operator by appearing to offer safety which is actually
non - existent. Furthermore, in wet weather, flash overs may occur when
the boom approaches high - voltage lines.
A820196_Appendix_B −4_0704 B425

Operation
Caution
The programmed limits are only monitored if you have selected
the “Move end hose” operating mode (selector switch in switch
position 2).
ÁÁ
ÁÁ
Á Á
Á
A820196_Appendix_B −4_0704 31
Always observe the placing boom during semi - automatic operation so

that you can foresee potential collisions with obstacles in good time.
B426 A820196_Appendix_B −4_0704

Operation
Starting position
ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ A820196_Appendix_B −4_0704 32
" First bring the boom into the starting position.
Á
Á Á
Á Á
A820196_Appendix_B −4_0704 33
position 4.
A820196_Appendix_B −4_0704 B427

Operation
4.6.1 Programming the upper limit
1
ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ A820196_Appendix_B −4_0704 34
1 Upper limit
2 Zero line
" Guide the boom tip to just below the hall ceiling.
ÁÁ
ÁÁ
Á Á
Á
A820196_Appendix_B −4_0704 35
" Briefly push the “Storing and deleting” toggle switch up.
å The upper limit is programmed.
B428 A820196_Appendix_B −4_0704

Operation
4.6.2 Programming the lower limit
1
3
A820196_Appendix_B −4_0704 36
1 Upper limit
2 Zero line
3 Lower limit
" Guide the boom tip to just above the ground.
Á
Á
Á Á
Á
A820196_Appendix_B −4_0704 37
" Briefly push the “Storing and deleting” toggle switch up.
å The lower limit is programmed.
A820196_Appendix_B −4_0704 B429

Operation
4.6.3 Moving the end hose within the limits
ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ A820196_Appendix_B −4_0704 38
" Move the placing boom into the starting position.
ÁÁ
ÁÁÁ
Á Á
A820196_Appendix_B −4_0704 39
" Move the EBC selector switch on the radio remote control
to sswitch position 2.
B430 A820196_Appendix_B −4_0704

Operation
Á
Á
ÁÁÁÁ
A820196_Appendix_B −4_0704 40
" Move the end hose using the right - hand joystick.
å The positions of all the arms are adjusted under computer con−
trol.
å The arms only move within the corridor of the upper and lower
limits.
ÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉÉ A820196_Appendix_B −4_0704 41
A820196_Appendix_B −4_0704 B431

Operation
4.6.4 Deleting limits
Note
All the stored values are automatically deleted if you switch off the truck
engine ignition or disengage the power take - off.
ÁÁ
ÁÁ
Á Á
Á
A820196_Appendix_B −4_0704 42
position 4.
ÁÁ
ÁÁÁÁ
Á
A820196_Appendix_B −4_0704 43
" Briefly push the “Storing and deleting” toggle switch down.
å Both the limits are deleted.
B432 A820196_Appendix_B −4_0704

Operation
4.7 Boom Damping A placing boom may bounce as a result of the boom position or the
pumping rate. This can cause the following problems:
- The hoseman can no longer guide the end hose.
- The concrete splashes.
- The end hose jumps out of the formwork.
- The formwork could be damaged.
Note
The boom damping functions at any of the switch positions of the
selector switch.
Boom damping is automatically activated as long as you are operating

one of the two joysticks. You must steer the left - hand joystick to the left
or right to activate boom damping if you are pumping without moving the
placing boom (e. g. filling in formwork).
Activating boom
damping
ÁÁ
ÁÁ
ÁÁÁÁ
A820196_Appendix_B −4_0704 44
" Keep the left - hand joystick positioned to the left or right.
A820196_Appendix_B −4_0704 B433

Operation
B434 A820196_Appendix_B −4_0704

Index
Numbers Boom movements, 2 – 7, 5 – 51

- Danger zone, 2 – 8
12/24 volt converter box, 3 — 22 - Hand signals, 5 – 55
- Horn, 5 – 53
- Prohibited activities, 5 – 51
A - Uncontrolled boom movements, 5 – 54
- Uncontrolled sinking as a result of hydraulic fluid cooling,
Accumulator, 3 — 62 5 – 53
- Maintenance, 6 – 31 Bouncing boom, 5 – 72
- Troubleshooting, 7 – 7
Brand name, B1 — 2
Accumulator dump cock, 3 — 62
Breaks in pumping, 5 – 75
Accumulator dump valve, 3 — 62
Additional lubrication procedure, 6 – 116
Agitator, Emergency operation, 3 — 61 C
Agitator hopper, Pumping operations, 5 – 71 Cable remote control, 3 — 37
Agitator lever, 3 — 58 - Boom speed, 5 – 31
Agitator safety cut -out, agitator shut -off valve, 3 — 60 - Restarting the pump, 5 – 32
- Setup, 5 – 27
Agitator safety cutout, Inspection, 5 – 7
Catch basket, 5 – 83
Agitator shut -off valve, 3 — 60
Central gauge port, 3 — 66
Aircuff, 3 — 75
- Regulator, 3 — 76 Central module control cabinet, Multiple display, 3 — 24
Antennae, Radio, telephone etc., 3 — 43 Centralized lubrication system, 6 – 113
- Additional lubrication procedure, 6 – 116
Automatic brackets, End hose, 3 — 72
- Fault, 6 – 115
Auxiliary water tank, 3 — 82 - Fault display, 6 – 114
- Cleaning, 6 – 105 - Filling the lubricant reservoir, 6 – 113
- Grease, 6 – 9
- Indicator lamps, 3 — 35
B - Low temperature grease, 6 – 9
- Technical data, 3 — 35
Bad weather, 2 – 4, 5 – 52
Changing diesel fuel filter for transfer tank, 3 — 84,
Ball-bearing slewing ring, Connecting bolts, 6 — 99 6 – 101, 6 – 102
Blockages, 5 – 77 Charging and gauging kit, 6 – 29
Boom Cleaning
- Bounce, 5 – 72 - Auxiliary water tank, 6 – 105
- Deck and boom pipe length, 3 — 10 - Catch basket, 5 – 83
- Description of the functions, 3 — 12 - Cement bags, 5 – 85
- Driving, 2 – 5 - Compressed air cleaning, 5 – 84
- Favorable boom position, 5 – 73 - Concrete pump, 5 – 81
- Folding when using One -Side -Support, 5 – 101 - Delivery cylinder, 5 – 93
- Impermissible working range, 5 – 63 - Delivery line, 5 – 87
- Troubleshooting, 7 – 8 - High -pressure water cleaning, 5 – 85
- Unfolding, 2 – 4, 5 – 56 - Hopper, 5 – 93
- Unfolding when using One -Side -Support, 5 – 64 - Leavings, 5 – 93
Boom control, Troubleshooting, 7 – 9 - Left over concrete, 5 – 82
Boom control unit, Inspection, 5 – 6 - Mark the water hose, 5 – 86
- Methods of cleaning delivery lines, 5 – 88
Boom damping, B3 — 8, B4 — 33
- Post -washing operations, 5 – 96
- Preparations for cleaning, 5 – 81
A820196_Appendix C−Index_0704 C–1
Index
-
-
S -tube, 5 – 93
Sponge ball, 5 – 83
D
- Suction cleaning, 5 – 89 Danger zone
- Truck superstructure, 5 – 96 - Boom movements, 2 – 8
- Wash -out adapter, 5 – 84 - Pumping operations, 5 – 70
Clearances - Setup site, 5 – 17
- Minimum clearance from pits, 5 – 14 - Supports, 5 – 35
- Safe clearances from pits, 5 – 15 Delivery cylinder, Cleaning, 5 – 93
Cold weather, 5 – 52 Delivery line
Components, Summary, 3 — 2 - Cleaning, 5 – 87
Compressed air cleaning, 5 – 84 - Description of the functions, 3 — 12
- Measuring the wall thickness (Machines with S transfer
Concrete brake, 3 — 73 tube), 6 — 89
Concrete pump, Description of the functions, 3 — 13 - Replacing, 6 – 117
Control block Delivery piston
- Boom, 3 — 57 - Piston replacement on the dual piston end -of-travel
- Mixer, 3 — 58 positioning system, 6 — 59
- Outrigger, 3 — 55 - Troubleshooting, 7 – 2
- Support, 3 — 54, 3 — 55, 3 — 56 Designated use, B2 — 2
Control cabinet Diesel fuel transfer tank, 3 — 84, 6 – 101
- 12V/24V converter, 3 — 22
Outrigger (swing leg) diesel fuel transfer tank,
- Additional control and operating elements, 3 — 27,
Changing the filter, 3 — 84, 6 – 101
3 — 29
- Central module control cabinet, 3 — 23 Driving, 4 – 2
- EBC, B3 — 10 - During the journey, 4 – 3
- OSS door module, 3 — 31 Driving position, Folding the boom when using
One -Side -Support, 5 – 101
Control devices
- Agitator lever, 3 — 58
- Boom control block, 3 — 57
- Cable remote control, 3 — 37 E
- Central module control cabinet, 3 — 23
EBC
- Control panel in the steps, 3 — 33
- Boom damping, B3 — 8, B4 — 33
- Hydraulic, 3 — 53
- Connector for setting up, B4 — 2
- Hydraulic fluid radiator, 3 — 65
- Control cabinet, B3 — 10
- OSS door module, 3 — 31
- EMERGENCY SHUT -DOWN, B3 — 11
- Output controller, emergency operation, 3 — 64
- How does EBC work?, B3 — 2
- Proximity switch junction box, 3 — 48
- Moving the end hose, B3 — 10, B4 — 24, B4 — 30
- Radio remote control, 3 — 38
- Preferred folding configuration, B4 — 20
- Support control block, 3 — 54
- Preferred position, B3 — 9, B4 — 13
- Vibrator, 3 — 79
- Programming the upper and lower limits, B4 — 25
- Water pump lever, 3 — 59
- Radio remote control operating elements, B3 — 5
Control panel, In the steps, 3 — 33 - Selector switch, B3 — 7
Coolant overheating, 3 — 25 - Starting up, B3 — 11, B4 — 2
Corner bearing load, 5 – 21 - Symbols for the control system, B3 — 2
- Outrigger pad usage, 5 – 17 - Unfolding and folding the placing boom
semi -automatically, B3 — 9, B4 — 4
- What is EBC?, B3 — 2
Econo -Gear, Use during pumping, 5 – 76
Effective Outrigger Pad Usage, 5 – 17, 5 – 18
C–2 A820196_Appendix C−Index_0704

Index
EMERGENCY SHUT--DOWN, EBC control cabinet, - Transfer tube, 3 — 13

B3 — 11, B4 — 3 Functional fluids, 6–8
EMERGENCY SHUT--DOWN button, 3 — 43, 3 — 45, Fuse, Troubleshooting, 7–11
5–6, B3 — 7
EMERGENCY SHUT--DOWN function, 5–5
Emergency stroke kit, 5–108 H
End hose, 3 — 72, 5–70
Hand signals
- Automatic brackets, 3 — 72
- Boom movements, 5–55
- Concrete brake, 3 — 73
- Pumping operations, 5–55
- Danger zone, 5–70
- Retaining rope, 3 — 74 High--pressure water cleaning, 5–85
- Weight limit, 3 — 74 High--voltage lines, B2 — 2
- with Flow restrictor, 3 — 73 High--voltage power lines, 2–9
Engine, Troubleshooting, 7–12 Highway travel, 4–2
EOC, Ergonic Output Control, 3 — 27 Hopper, Cleaning, 5–93
Ergonic Boom Control, Radio remote control, 3 — 39 Hopper grate safety switch, 3 — 51
Ergonic Output Control, 3 — 27 Hydraulic control, Description of the functions, 3 — 12,
3 — 53
Hydraulic fluid, 6–8
F - Full fluid change, 6–21
- Radiator, 3 — 65
Fault, Centralized lubrication system, 6–115
- Troubleshooting, 7–7, 7–10
Fault display, Centralized lubrication system, 6–114
Hydraulic fluid radiator, 3 — 65
Filling the lubricant reservoir, 6–113
Hydraulic oil tank, 3 — 86
Filter
Hydraulic system
- Boom filter, 5–4
- Accumulator maintenance, 6–31
- Vacuum filter, 5–4
- Charging and gauging kit, 6–29
Filter change, 6 — 43, 6 — 55
Hydraulic system diagnosis, Central gauge port, 3 — 66
- Pressure filter, 6 — 49
Filter functions
- Boom filter, 5–4
- Vacuum filter, 5–4 I
Flared screwed joint, 6–7 Icons, 1–3, B1 — 4
Flow restrictor on the end hose, 3 — 73 Impermissible working range, 2–11
Flushing water pump, 3 — 71
Function checks, 5–2, 6–27
- Agitator safety cutout, 5–7 K
- Boom control unit inspection, 5–6 KEP, Piston end--of--travel positioning, 6 — 59
- EMERGENCY SHUT--DOWN function, 5–5
- Filter functions, 5–4
- Proximity switch, 5–3
- Pump functions, 5–2
L
Function description, 3 — 12 Left over concrete, 5–82
- Boom, 3 — 12 - Cleaning, 5–93
- Concrete pump, 3 — 13 Level bubble, 3 — 69, 5–44
- Delivery line, 3 — 12
Level control, 3 — 29, 3 — 30, 3 — 78
- Hydraulic control, 3 — 12
- Outriggers, 3 — 12 Liability, Exclusion, B2 — 3
A820196_Appendix C--Index_0704 C–3

Index
Limits, B4 — 25 Mixer control block, 3 — 58

- Deleting a limit, B4 — 32 - Agitator lever, 3 — 58
- Moving the end hose, B4 — 30 Module control cabinet, 3 — 23
- Programming the lower limit, B4 — 29 - Additional control and operating elements, 3 — 27,
- Programming the upper limit, B4 — 28 3 — 29, 3 — 31
Loading, 4 – 8 Moving the end hose, B3 — 10, B4 — 24, B4 — 30
Lock Out -Tag Out Procedure, 6 – 2
Lubricant analysis, 6 – 9
Lubricants (recommended), 6 – 10 O
Lubrication Obstacles, 2 – 10
- Grease, 6 – 9 Oil cooler, Troubleshooting, 7 – 12
- M 43/47 RZ placing boom, 6 — 95
One -Side -Support, 5 – 45, 5 – 46
- S -Transfer tube, 6 — 67
- Folding the boom, 5 – 101
- TRDI 140 boom pedestal, 6 — 97
- Prohibited working range, 5 – 67
- Space requirement, 5 – 45
M
- Supporting the machine, 5 – 46
- Unfolding the boom, 5 – 64
Machine rating plate, 3 — 8 Open gear lubrication, 6 – 9
Maintenance cards Operating and control elements, Power take -off, 5– 9
- Changing the hydraulic fluid, 6 – 21 Operating procedures
- Changing the pressure filter element, 6 — 49 - Cable remote control setup, 5 – 27
- Changing the suction filter element, 6 — 43 - Cleaning the unit, 5 – 81
- Changing the ventilation filter element, 6 — 55 - Outriggers setup, 5 – 33
- Checking the connecting bolts on the ball -bearing slewing - Pre-operation inspection, 5 – 11
ring, 6 — 99 - Preliminary information, 5 – 2
- Delivery piston replacement on the dual piston - Pumping concrete with the emergency stroke kit, 5 – 108
end -of-travel positioning system, 6 — 59 - Radio remote control setup, 5 – 29
- Function checks, 6 – 27 - Teardown, 5 – 97
- Hose inspection and replacement, 6 — 37 - Unit setup, 5 – 14
- Lubricating the M 43/47 RZ placing boom, 6 — 95
Operation, 5 – 1
- Lubricating the TRDI 140 boom pedestal, 6 — 97
- Lubrication, 6 — 95 OSS
- Measuring the wall thickness (Machines with S transfer - (One-Side -Support), 5 – 45, 5 – 46
tube), 6 — 89 - Folding the boom, 5 – 101
- Performing maintenance on the accumulator, 6 – 29 - OSS equipment, 3 — 31
- Replacing the delivery line, 6 – 117 - Prohibited working range, 5 – 67
- Replacing the S -transfer tube, 6 – 69 - Supporting the machine, 5 – 46
- S -transfer tube wear parts, 6 – 69 - Unfolding the boom, 5 – 64
- Slewing gear transmission, 6 — 17 OSS equipment, 3 — 31
- Vacuum meter, 6 — 41
Output, Ergonic Output Control, 3 — 27
- Visual checks, 6 — 15
Output controller, Emergency operation, 3 — 64
Maintenance intervals, 6 – 3
Outrigger
Maintenance procedures
- Cleaning the auxiliary water tank, 6 – 105
- Adjusting accumulator pressure, 6 – 33
- Control block
- Checking accumulator pre -charge pressure, 6 – 32
Left side, 3 — 55
- Replacing accumulator bladder, 6 – 35
Right side, 3 — 56
Measuring the wall thickness, Machines with S transfer - Water tank, 3 — 82
tube, 6 — 89
Outrigger control block, 3 — 55

Index
Outrigger diesel fuel transfer tank Pumping operations, 3 — 25, 5 – 70

- Changing fuel filter, 6 – 102 - Agitator hopper, 5 – 71
- Draining the tank, 6 – 102 - Blockages, 5 – 77
Outriggers - Breaks in pumping, 5 – 75
- Description of the functions, 3 — 12 - Calm pumping, 5 – 72
- Setup, 5 – 33 - Cooling, 5 – 78
- Snaplock, 5 – 34, 5 – 106, 6 – 107 - Cooling, additional, 5 – 79
- Temperature-related cylinder movements, 5 – 53 - Damping valve, 5 – 74
- Econo -Gear, 5 – 76
Overview diagram, 43Z, 3 — 2
- Favorable boom position, 5 – 73
- Hand signals, 5 – 55
P
- Overheating, 5 – 78
- Pumping, 5 – 75
Personnel qualifications, 2 – 2 - Restarting, 5 – 79
- Starting pumping, 5 – 74
Pipe length and diameter, Plate, 3 — 10
- Sucking in air, 5 – 71
Placing boom
- Boom damping, B3 — 8, B4 — 33
- Folding, B4 — 9
- Moving the end hose, B3 — 10, B4 — 24
Q
- Preferred folding configuration, B4 — 20 Quench valve, 3 — 75
- Preferred position, B3 — 9, B4 — 13
- Preferred position for arm 1, B4 — 14
- Preferred position for arm 5, B4 — 17
- Programming the upper and lower limits, B4 — 25
R
- Unfolding, B4 — 5 Radio remote control
- Unfolding and folding semi -automatically, B3 — 9, - Receiver, 3 — 42
B4 — 4 - Setup, 5 – 29
- Upper and lower limit, B3 — 8 - Transmitter, 3 — 38
Power take -off, NA and NMV, 5 – 8 EBC, 3 — 39
- Troubleshooting, 7 – 9, 7 – 12
Preferred folding configuration, B4 — 20
- Storing, B4 — 22, B4 — 23 Range diagram, 43Z, 3 — 11
Preferred position, B3 — 9, B4 — 13 Rating plate, Machine, 3 — 8

- Arm 1, B4 — 14 Reaches, Extending, 2 – 6
- Arm 5, B4 — 17 Remote control, 5 – 26
- Deleting, B4 — 16, B4 — 19
Replacing, Accumulator bladder, 6 – 35
- Storing, B4 — 16, B4 — 19
Restarting the pump, With cable remote control, 5 – 32
Profiled ring joint, 6 – 7
Retaining rope, 3 — 74
Prohibited activities, 5 – 51
Proximity switch, 3 — 48
- Connector with LEDs, 3 — 50
- Function check, 5 – 3
S
Proximity switch junction box, 3 — 48 S -Transfer tube, Measuring the wall thickness, 6 — 89
Pump, Troubleshooting, 7 – 3, 7 – 10, 7 – 13 S -Transfer tube, Lubrication, 6 — 67
Pump functions, 5 – 2 S -Transfer tube
- Stroke length, 5 – 3 - Cleaning, 5 – 93
- Stroke time, 5 – 3 - Replacing, 6 – 69
- Switchover, 5 – 2 - Wear parts, 6 – 69
Safety equipment, 3 — 5

Index
Safety regulations, 2 – 1, 2 – 2 Support block, 5 – 22

- Basic principle, B2 — 2 Supporting ground, 5 – 19
- Defective components, B2 — 3
Supports
- Designated use, B2 — 2
- Danger zone, 5 – 35
- Exclusion of liability, B2 — 3
- Forward support legs
- High -voltage lines, B2 — 2
Extending, 5–36
- Use contrary to the designated use, B2 — 2
Lower, 5–40
Service operation, 3 — 25 - Level bubble, 3 — 69
Set-up site, Space requirement, 5 – 13 - One -Side -Support, 5 – 46
Setting up, 5 – 11 - OSS, 5 – 46
- Cable remote control system, 5 – 27 - Rear support feet, 5 – 42
- Outriggers, 5 – 33 Extending, 5–38
- Radio remote control system, 5 – 29 Lower, 5–42
- Unit, 5 – 14 Symbols, 1 – 3
Setup site - EBC control, B3 — 2
- Calculation examples of minimum clearance from pits, - In the Operating Instructions, B1 — 4
5 – 16 Symbols for the control system, 3 — 14
- Corner bearing load, 5 – 21 - Boom, 3 — 20
- Danger zone, 5 – 17 - Concrete pump, 3 — 14, 3 — 15
- Minimum clearance from pits, 5 – 14 - Electrical system, 3 — 17, 3 — 18
- Safe clearance from pits, 5 – 15 - Engine, 3 — 16
- Space requirement, 5 – 17 - Hydraulic system, 3 — 19
- support block, 5 – 22 - Outriggers, 3 — 19
- Supporting ground, 5 – 19
- Table of timber block lengths, 5 – 23
- Timber blocks, 5 – 22 T
Signaller, 2 – 7
Teardown, 5 – 97
Sinking of the boom, 5 – 54
Technical data, 3 — 8
- Cooling of the hydraulic fluid, 5 – 53
- Centralized lubrication system, 3 — 35
Slewing gear transmission
Technical description
- Condensate water, 6 — 18
- Flushing water pump, 3 — 71
- Maintenance, 6 — 17
- Functions, 3 — 1
- Oil, 6 — 18
Thunderstorms, 5 – 52
Snaplock, Outriggers, 5 – 34, 5 – 106, 6 – 107
Tightening torques
Space requirement, 5 – 13, 5 – 17
- Flared screwed joint, 6 – 7
- Normally supported, 5 – 13
- General, 6 – 5
- One -Side -Support, 5 – 14
Timber blocks, 5 – 22, 5 – 23
Squeeze valve, 3 — 75
- Toggle switch, 3 — 29, 3 — 78 Towing, 4 – 4
Starting up Transfer tube
- EBC control cabinet, B3 — 11, B4 — 3 - Description of the functions, 3 — 13
- EMERGENCY SHUT -DOWN, B3 — 11, B4 — 3 - Troubleshooting, 7 – 6
- With EBC, B4 — 2 Transfer tube damping, 3 — 62
Static charging, 2 – 9 Transmission, Econo -gear, 5 – 76
Storms, 2 – 4 Transmission oil, 6 – 9
Summary of the components, 3 — 2 Transport position, Retracting the outriggers, 5 – 106
Support, Extending for One -Side -Support, 5 – 46 Travel
Support area, Table of timber block lengths, 5 – 23 - Driving, 4 – 1

Index
- Towing, 4 – 1
TRDI 140, Lubrication, 6 — 97
Truck superstructure, Cleaning, 5 – 96
U
Uncontrolled boom movements, 5 – 54
Use contrary to the designated use, B2 — 2
V
Vacuum meter, Replacement, 6 — 41
Vibrator, 3 — 79
Visual checks, 6 — 15
W
Wash -out adapter, 5 – 84
Water hose, Marking, 5 – 86
Water pump, 3 — 59
- Emergency operation, 3 — 61
Water tank, 3 — 70
Water tank heater, 3 — 80
Wind speed, 5 – 52
Wind speeds, 2 – 4
Working area
- Impermissible working area, boom, 5 – 63
- Impermissible working range, boom, 2 – 11

Index

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Operating Instruction

for machine operator and maintenance staff

keep by the machine

Machine no. 210602351

España Putzmeister Ibérica S.A. +34--91--428 81 00 recepcion@putzmeister.es

France Putzmeister France +33--169 39 69 39 Infopmf@putzmeister.fr

Great Putzmeister Limited +44--1246--2642 00 info@putzmeister.co.uk

South Putzmeister S.A. (Pty) Ltd. +27--11--794--37 90 pmsa@icon.co.za

Korea Putzmeister Korea Co. Ltd. +82--2--569--7201 pmk@putzmeister.co.kr

1 Guide to the Operating Instructions 1–1

1.2 Icons and Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3

2 Safety Regulations . . . . . . . . . . . . . . . 2–1

2.2 Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2

2.3 Unfolding the Placing Boom . . . . . . . . . . . . . . . . . . . . . . . . . 2–4

2.4 Bad Weather and Storms . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4

2.5 Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5

2.6 Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5

2.7 Extending the Reach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–6

2.8 Signaller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–7

2.9 Boom Movements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–7

3 General Technical Description . . . . 31

3.2 Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 5

3.3 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 8

3.4 Machine Rating Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 8

3.5 Boom Rating Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 9

3.6 Boom and Deck Delivery/Adapter Pipe Rating Plate . . . 3 — 10

3.7 43Z Range Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 11

3.8 Description of the Functions . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 12

3.9 Symbols for the Control System . . . . . . . . . . . . . . . . . . . . . . 3 — 14

3.10 Electrical Control Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 21

3.10.10 Proximity Switch Junction Box . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 48

3.11 Hydraulic Control Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 53

3.12 Mixer Control Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 58

3.13 Central Gauge Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 66

3.14 Other Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 68

3.15 Outrigger (Swing Leg) Water Tank . . . . . . . . . . . . . . . . . . . . 3 — 82

3.16 Outrigger (Swing Leg) Diesel Fuel Transfer Tank

3.17 Hydraulic oil tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 — 86

4.2 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–4

4.3 Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–8

5.2 Function Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2

5.3 Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–11

Radio remote control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–29

5.4 Special Case of “One - Side - Support” . . . . . . . . . . . . . . . . . 5–45

5.5 Boom Movements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–50

5.6 Hand Signals for Boom and Pumping Operations . . . . . . 5–54

5.7 Unfolding the 5 RZ Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–55

5.8 Unfolding the Boom when using

5.9 Pumping Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–69

6.1 Maintenance Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3

6.2 General Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5

6.3 Functional Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–8

6.4 Recommended Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–10

6.6 Slewing Gear Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 17

6.7 Changing the Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . 6–21

6.8 Function Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–27

6.9 Performing Maintenance on the Accumulator . . . . . . . . . 6–29

6.10 Hose Inspection and Replacement . . . . . . . . . . . . . . . . . . . 6 — 37

6.11 Vacuum Meter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 6 — 41

6.12 Changing the Suction Filter Element . . . . . . . . . . . . . . . . . . 6 — 43